Pre-strained laminates and methods for making the same

ABSTRACT

A method of forming a three-dimensional laminate for an absorbent article is provided. The method comprises providing a first nonwoven layer, providing a second nonwoven layer, and applying a pre-strain force to the first nonwoven layer or to the second nonwoven layer. The method comprises joining the first nonwoven layer to the second nonwoven layer while the first nonwoven layer or the second nonwoven layer is in a pre-strained condition, and releasing the pre-strain force to form the three-dimensional laminate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Patent Application Ser. Nos. 62/076,043, filed on Nov. 6,2014, and 62/177,405, filed on Mar. 13, 2015, the entire disclosures ofwhich are hereby incorporated by reference.

FIELD

The present disclosure generally relates to webs, apertured webs,patterned apertured webs, zonal patterned apertured webs, laminates,pre-strained laminates, moiré effect laminates, and methods for makingthe same. The webs, apertured webs, patterned apertured webs, zonalpatterned apertured webs, laminates, pre-strained laminates, and moiréeffect laminates are particularly suited for use in disposable absorbentarticles, such as diapers, adult incontinence products, training pants,feminine hygiene products, wipes, dusting substrates, cleaningsubstrates, and any other suitable consumer products or other products.

BACKGROUND

Apertured webs are sometimes useful in disposable absorbent products andother consumer products. These apertured webs typically have uniformlysized and shaped circular or ovate apertures throughout their area. Thecircular or ovate apertures may be uniformly spaced in the cross-machinedirection and in the machine direction with respect to each other. Theseuniform aperture patterns provide webs that have the same amount offluid penetration and/or absorbency throughout their area owing to theuniform circular or ovate aperture designs. Furthermore, land areas(i.e., non-apertured portions) in these apertured webs typically havethe same size, shape, orientation, and spacing with respect to eachother. While such uniform apertured webs may be desirable in someapplications, other applications would benefit from improved aperturedwebs. Furthermore, these apertured webs are typically planar, but someconsumers may desire three-dimensional features and other features.

SUMMARY

The patterned apertured webs of the present disclosure provide patternsof nonhomogeneous apertures that have different sizes, shapes, and/orAbsolute Feret Angles. This allows the webs to have better depthperception, improved fluid handling properties, and/or aestheticallypleasing appearances relative to apertured webs that have uniformlysized and shaped, homogeneous apertures. Laminates having at least onepre-strained layer of the present disclosure, whether comprisingpatterned apertured webs, apertured webs, or not, providethree-dimensional features in the laminates, thereby providing consumerpreferred executions that, in one example, may keep bodily exudates awayfrom the skin of a wearer or user. Moiré effect laminates may also beprovided. Outer covers, and other components of absorbent articles alsobenefit from these patterned apertured webs, pre-strained laminates,moiré effect laminates, and other non-pre-strained laminates of thepresent disclosure. Methods of making the patterned apertured webs,moiré effect laminates, and pre-strained or non-pre-strained laminatesare also provided.

In a form, the present disclosure is directed, in part, to a patternedapertured web. The patterned apertured web comprises a plurality of landareas in the patterned apertured web and a plurality of aperturesdefined in the patterned apertured web. At least some of the land areassurround at least some of the apertures. The patterned apertured web hasan Effective Open Area in the range of about 5% to about 50%, accordingto the Aperture Test herein. The patterned apertured web has a pluralityof Interaperture Distances, according to the Aperture Test herein. TheInteraperture Distances have a distribution having a median and a mean,wherein the mean is greater than the median.

In a form, the present disclosure is directed, in part, to a patternedapertured web. The patterned apertured web comprises a plurality of landareas in the patterned apertured web. At least some of the land areashave a width of at least 5 mm. The patterned apertured web comprises aplurality of apertures defined in the patterned apertured web. At leastsome of the land areas surround at least some of the plurality ofapertures. The plurality of apertures are non-homogeneous in a repeatunit such that at least three of the apertures have a different size, adifferent shape, or a different Absolute Feret Angle, according to theAperture Test herein. The plurality of the apertures have an EffectiveAperture Area in a range of about 0.3 mm² to about 15 mm², according tothe Aperture Test herein. The patterned apertured web has an EffectiveOpen Area in a range of about 5% to about 50%, according to the ApertureTest herein.

In a form, the present disclosure is directed, in part, to a patternedapertured web. The patterned apertured web comprises a plurality of landareas in the patterned apertured web and a plurality of aperturesdefined in the patterned apertured web, wherein at least some of landareas surround at least some of the apertures. The plurality ofapertures are non-homogeneous in a repeat unit such that at least threeof the apertures have a different size or a different shape. Thepatterned apertured web has an Effective Open Area in the range of about5% to about 50%, according to the Aperture Test herein.

In a form, the present disclosure is directed, in part, to a patternedapertured web comprising a plurality of first arrays forming a firstzone in the patterned apertured web. At least some of the first arrayscomprise a first plurality of land areas and a first plurality ofapertures. At least some of the first plurality of land areas surroundat least some of the first plurality of apertures. The first pluralityof apertures in the first zone have a plurality of InterapertureDistances, according to the Aperture Test herein. The InterapertureDistances of the first zone have a first distribution having a firstmean and a first median. The first mean is greater than the first medianby at least 4%. The first arrays comprise an Effective Open Area in therange of about 5% to about 50%, according to the Aperture Test herein.The patterned apertured web comprises a plurality of second, differentarrays forming a second zone. At least some of the second arrayscomprise a second plurality of land areas and a second plurality ofapertures. At least some of the second land areas surround at least someof the second plurality of apertures. The second plurality of aperturesin the second zone have a plurality of Interaperture Distances,according to the Aperture Test herein. The Interaperture Distances ofthe second zone have a second distribution having a second mean and asecond median. The second mean is greater than the second median. Thesecond arrays comprise an Effective Open Area of about 5% to about 50%,according to the Aperture Test herein.

In a form, the present disclosure is directed, in part, to a patternedapertured web. The patterned apertured web comprises a plurality offirst arrays forming a first zone in the patterned apertured web. Atleast some of the first arrays comprise a first plurality of land areasand a first plurality of non-homogeneous apertures. At least some of thefirst plurality of land areas surround at least some of the firstplurality of apertures. The first plurality of apertures have an AverageAbsolute Feret Angle of greater than about 20 degrees, according to theAperture Test herein. The first arrays comprise an Effective Open Areain the range of about 5% to about 50%, according to the Aperture Testherein. The patterned apertured web comprises a plurality of second,different arrays forming a second zone in the patterned aperture web. Atleast some of the second arrays comprise a second plurality of landareas and a second plurality of non-homogeneous apertures. At least someof the second plurality of land areas surround at least some of thesecond plurality of apertures. The second arrays comprise an EffectiveOpen Area of about 5% to about 50%, according to the Aperture Testherein.

In a form, the present disclosure is directed, in part, to a patternedapertured web. The patterned apertured web comprises a layer comprisinga plurality of apertures and a plurality of land areas. The plurality ofapertures comprise a first set of apertures in a first zone and a secondset of apertures in a second zone. The first set of apertures in thefirst zone have Interaperture Distances, according to the Aperture Testherein. Interaperture Distances of the first set of apertures have afirst distribution having a first mean and a first median. The firstmean is different than the first median. The second set of apertures inthe second zone have Interaperture Distances, according to the ApertureTest herein. The Interaperture Distances of the second set of apertureshave a second distribution having a second mean and a second median. Thesecond mean is different than the second median. The first and secondsets of apertures have different patterns.

In a form, the present disclosure is directed, in part, to a laminate.The laminate comprises a first layer comprising a plurality of loweropacity zones positioned within a higher opacity zone. The plurality oflower opacity zones form a first pattern. The laminate comprises asecond layer comprising a second pattern. The first layer isintermittently joined to the second layer to form the laminate. Thelaminate comprises a non-joined span of the first and second layershaving a dimension of at least about 20 mm. A first portion of thesecond pattern is visible through at least some of the plurality oflower opacity zones when the first layer, within the non-joined span, isin a first position relative to the second layer, within the non-joinedspan. A second portion of the second pattern is visible through at leastsome of the plurality of lower opacity zones when the first layer,within the non-joined span, is in a second position relative to thefirst layer, within the non-joined span.

In a form, the present disclosure is directed, in part, to an absorbentarticle comprising a laminate. The laminate comprises a first nonwovenlayer comprising a plurality of lower opacity zones positioned within ahigher opacity zone. The plurality of lower opacity zones form a firstpattern. The laminate comprises a second layer comprising a secondpattern. The first layer is intermittently joined to the second layer toform the laminate. The laminate comprises a non-joined span of the firstand second layers having a dimension of at least about 20 mm. A firstportion of the second pattern is visible through at least some of theplurality of lower opacity zones when the first layer, within thenon-joined span, is in a first position relative to the second layer,within the non-joined span. A second portion of the second pattern isvisible through at least some of the plurality of lower opacity zoneswhen the first layer, within the non-joined span, is in a secondposition relative to the first layer, within the non-joined span.

In a form, the present disclosure is directed, in part, to an absorbentarticle comprising a laminate. The laminate comprises a first nonwovenlayer comprising a plurality of apertures in a first pattern and asecond layer comprising a second, different pattern. The first layer isintermittently joined to the second layer to form the laminate. Thelaminate comprises a non-joined span of the first and second layershaving a dimension of at least about 30 mm. A first portion of thesecond pattern is visible through at least some of the plurality ofapertures when the first layer, within the non-joined span, is in afirst position relative to the second layer, within the non-joined span.A second portion of the second pattern is visible through at least someof the plurality of apertures when the first layer, within thenon-joined span, is in a second position relative to the first layer,within the non-joined span.

In a form, the present disclosure is directed, in part, to a method ofproducing a patterned apertured web. The method comprises providing aweb having a central longitudinal axis. The web comprises a plurality ofoverbonds extending substantially parallel to the central longitudinalaxis. The method comprises conveying the web in a machine direction thatis substantially parallel to a direction of extension of the centrallongitudinal axis of the web. The method comprises stretching the web ina cross-machine direction that is substantially perpendicular to themachine direction to cause at least some of the overbonds to at leastpartially rupture and at least partially form patterned apertures in theweb. At least some of the patterned apertures have Absolute FeretAngles, according to the Aperture Test herein, of at least about 20degrees. At least some of the patterned apertures have an Aspect Ratio,according to the Aperture Test herein, in the range of about 2:1 toabout 6:1.

In a form, the present disclosure is directed, in part, to a method offorming patterned apertures in a web. The method comprises providing aweb having a central longitudinal axis, conveying the web in a machinedirection that is substantially parallel to the central longitudinalaxis, and creating a plurality of overbonds in the web. The overbondshave central longitudinal axes that are substantially parallel to thecentral longitudinal axis of the web. The method comprises stretchingthe web in a cross-machine direction that is substantially perpendicularto the machine direction to at least partially form patterned aperturesin the web at, at least some of the overbonds. At least some of thepatterned apertures have Absolute Feret Angles, according to theAperture Test herein, of at least about 20 degrees. The at least some ofthe patterned apertures have an Aspect Ratio, according to the ApertureTest herein, of greater than about 2:1.

In a form, the present disclosure is directed, in part, to a method ofproducing a patterned apertured web. The method comprises providing aweb having a central longitudinal axis. The web comprises a plurality ofoverbonds extending substantially parallel to the central longitudinalaxis. The method comprises conveying the web in a machine direction thatis substantially parallel to a direction of extension of the centrallongitudinal axis of the web. The method comprises stretching the web ina cross-machine direction that is substantially perpendicular to themachine direction to cause at least some of the overbonds to at leastpartially rupture and at least partially form patterned apertures in theweb. At least some of the patterned apertures have Absolute FeretAngles, according to the Aperture Test herein, that are at least about25 degrees. At least some of the patterned apertures have an AspectRatio, according to the Aperture Test herein, in the range of about 2:1to about 6:1. At least three of the apertures are nonhomogeneous.

In a form, the present disclosure is directed, in part, to a laminatecomprising a first nonwoven layer comprising a plurality of aperturesand a second nonwoven layer. One of the first and second nonwoven layersis a pre-strained layer and is joined to the other one of the first andsecond nonwoven layers. The other one of the first and second nonwovenlayers is a non-pre-strained layer. The pre-strained layer and thenon-pre-strained layer together form a three-dimensional laminate.

In a form, the present disclosure is directed, in part, to a laminatecomprising a first nonwoven layer comprising a patterned apertured webcomprising a plurality of apertures and a second nonwoven layer. One ofthe first and second nonwoven layers is a pre-strained layer and isjoined to the other one of the first and second nonwoven layers. Theother one of the first and second nonwoven layers is a non-pre-strainedlayer. The pre-strained layer and the non-pre-strained layer togetherform a three-dimensional laminate. The plurality of apertures haveInteraperture Distances, according to the Aperture Test herein. TheInteraperture Distances have a distribution having a mean and a median,wherein the mean is greater than the median.

In a form, the present disclosure is directed, in part, to a laminatecomprising a first nonwoven layer comprising a patterned apertured webcomprising plurality of apertures and a second nonwoven layer. One ofthe first and second nonwoven layers is a pre-strained layer and isjoined to the other one of the first and second nonwoven layers. Theother one of the first and second nonwoven layers is a non-pre-strainedlayer. The pre-strained layer and the non-pre-strained layer togetherform a three-dimensional laminate. The first nonwoven layer or thesecond nonwoven layer comprises an indicia or a patterned adhesive thathas a different color than the first nonwoven layer or the secondnonwoven layer. The plurality of apertures have Interaperture Distances,according to the Aperture Test herein. The Interaperture Distances havea distribution having a mean and a median. The mean is greater than themedian. The laminate is free of any elastic strands or elastic films.

In a form, the present disclosure is directed, in part, to an absorbentarticle. The absorbent article comprises a liquid permeable topsheet ona wearer-facing side of the absorbent article, a garment-facing laminateon a garment-facing side of the absorbent article. The garment-facinglaminate comprises a first nonwoven layer and a second layer joined tothe first nonwoven layer. The first nonwoven layer comprises a pluralityof apertures. At least 3 of the plurality of apertures in a repeat unithave a different size, a different shape, or a different Absolute FeretAngle, according to the Aperture Test herein. The absorbent articlecomprises an absorbent core disposed at least partially intermediate theliquid permeable topsheet and the garment-facing laminate.

In a form, the present disclosure is directed, in part, to an absorbentarticle. The absorbent article comprises a liquid permeable topsheet ona wearer-facing side of the absorbent article and a garment-facinglaminate on a garment-facing side of the absorbent article. Thegarment-facing laminate comprises a first nonwoven layer and a secondlayer joined to the first nonwoven layer when the first nonwoven layeror the second layer is in a pre-strained condition and when the other ofthe first nonwoven layer or the second layer is in a non-pre-strainedcondition to form a three-dimensional material. The first nonwoven layercomprises a plurality of apertures. The absorbent article comprises anabsorbent core disposed at least partially intermediate the liquidpermeable topsheet and the garment-facing laminate.

In a form, the present disclosure is directed, in part, to an absorbentarticle. The absorbent article comprises a liquid permeable topsheet ona wearer-facing side of the absorbent article and a garment-facing layeron a garment-facing side of the absorbent article. The garment-facinglayer comprises a first zone comprising a plurality of overbonds and asecond zone comprising a plurality of apertures. At least 3 of theplurality of apertures in a repeat unit have a different size, adifferent shape, or a different Absolute Feret Angle, according to theAperture Test herein. The absorbent article comprises a liquidimpermeable backsheet and an absorbent core disposed at least partiallyintermediate the liquid permeable topsheet and the backsheet.

In a form, the present disclosure is directed, in part, to an absorbentarticle. The absorbent article comprises a liquid permeable topsheet ona wearer-facing side of the absorbent article and a garment-facinglaminate on a garment-facing side of the absorbent article. Thegarment-facing laminate comprises a first nonwoven layer and a secondnonwoven layer joined to the first nonwoven layer. The first nonwovenlayer comprises a plurality of apertures. The absorbent articlecomprises an absorbent core disposed at least partially intermediate theliquid permeable topsheet and the garment-facing laminate.

In a form, the present disclosure is directed, in part, to a method offorming a three-dimensional laminate for an absorbent article. Themethod comprises providing a first nonwoven layer, providing a secondnonwoven layer, and applying a pre-strain force to the first nonwovenlayer or to the second nonwoven layer. The method comprises joining thefirst nonwoven layer to the second nonwoven layer while the firstnonwoven layer or the second nonwoven layer is in a pre-strainedcondition, and releasing the pre-strain force to form thethree-dimensional laminate.

In a form, the present disclosure is directed, in part, to a method offorming a three-dimensional laminate for an absorbent article. Themethod comprises providing a first layer, providing a separate, secondlayer, and applying a pre-strain force to the first layer or to thesecond layer. The method comprises overbonding the first layer and thesecond layer while the first layer or the second layer is in apre-strained condition to join the first layer and the second layer, andreleasing the pre-strain force to form the three-dimensional laminate.

In a form, the present disclosure is directed, in part, to a method offorming a three-dimensional laminate for an absorbent article. Themethod comprises providing a nonwoven first layer, providing a separate,nonwoven second layer, and applying a pre-strain force substantially inthe machine direction to the first nonwoven layer or to the secondnonwoven layer. The method comprises overbonding the first layer and thesecond layer while the first layer or the second layer is in apre-strained condition to join the first layer and the second layer. Themethod comprises stretching the first and second nonwoven layers in asubstantially cross-machine direction to cause at least some of theoverbonds to at least partially rupture and at least partially formapertures in the first and second nonwoven layers, and releasing thepre-strain force to form the three-dimensional laminate. Thethree-dimensional laminate is free of elastic strands or elastic films.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which the designations are used todesignate substantially identical elements and in which:

FIGS. 1-4 are photographs of portions of example patterned aperturedwebs in accordance with the present disclosure;

FIG. 5 is a schematic representation of a cross-sectional view of apatterned apertured web having two layers, with one layer havingpatterned apertures and the other layer being non-apertured inaccordance with the present disclosure;

FIG. 6 is a schematic representation of a cross-sectional view of apatterned apertured web having two layers, with both layers havingpatterned apertures and with the apertures in the layers being alignedin accordance with the present disclosure;

FIG. 7 is a schematic representation of a cross-sectional view of apatterned apertured web having two layers, with both layers havingpatterned apertures and with the apertures in one layer being fullyoverlapped by land areas in the other layer in accordance with thepresent disclosure;

FIG. 8 is a schematic representation of a cross-sectional view of apatterned apertured web having two layers, with both layers havingpatterned apertures and with the apertures in one layer being partiallyoverlapped by land areas in the other layer in accordance with thepresent disclosure;

FIG. 9 is a schematic representation of a cross-sectional view of apatterned apertured web having two layers, with a first patternedapertured layer and a second non-apertured layer and with printing orink on one of the layers in accordance with the present disclosure;

FIG. 10 is a schematic representation of a cross-sectional view of apatterned apertured web having two layers, with a first patternedapertured layer and a second non-apertured layer and with a coloredadhesive on one of the layers or positioned intermediate the layers inaccordance with the present disclosure;

FIGS. 11-15 are example patterned apertured webs in accordance with thepresent disclosure;

FIG. 16 is a schematic representation of an example method for producingthe patterned apertured webs of the present disclosure in accordancewith the present disclosure;

FIG. 17 is a perspective view of a web weakening arrangement of FIG. 16in accordance with the present disclosure;

FIG. 18 is a photograph of an example roller that can be used as roller110 in the weakening arrangement of FIG. 17 in accordance with thepresent disclosure;

FIGS. 19-23 are example overbond patterns for roller 110 of FIG. 17 usedto produce patterned apertured webs in accordance with the presentdisclosure;

FIG. 24 is a perspective view of an incremental stretching system of themethod of FIG. 16 in accordance with the present disclosure;

FIG. 25 is an enlarged view showing the details of teeth of theincremental stretching system of FIG. 24 in accordance with the presentdisclosure;

FIG. 26 is a perspective view of an example cross machine directionaltensioning apparatus of the method of FIG. 16 in accordance with thepresent disclosure;

FIG. 27 is a schematic representation of a front view of an examplecross machine directional tensioning apparatus with outer longitudinalportions in an unexpanded and non-angled position relative to a middleportion in accordance with the present disclosure;

FIG. 28 is a schematic representation of a front view of the crossmachine directional tensioning apparatus of FIG. 27 with the outerlongitudinal portions in a longitudinally expanded position relative tothe middle portion in accordance with the present disclosure;

FIG. 29 is a schematic representation of a front view of the crossmachine directional tensioning apparatus of FIG. 27 with the outerlongitudinal portions in an angled and expanded position relative to themiddle portion in accordance with the present disclosure;

FIG. 30 is a schematic representation of a front view of a cross machinedirectional tensioning apparatus with outer longitudinal portions fixedin an angled position relative to a middle portion in accordance withthe present disclosure;

FIG. 31 is an example overbond pattern for the roller 110 of FIG. 17 inaccordance with the present disclosure;

FIG. 32 is a photograph of an example patterned apertured web producedusing the overbond pattern of FIG. 31 and having been subjected to a 25%cross directional stretch using the equipment illustrated in FIG. 26 inaccordance with the present disclosure;

FIG. 33 is a photograph of an example patterned apertured web producedusing the overbond pattern of FIG. 31 and having been subjected to a 35%cross directional stretch using the equipment illustrated in FIG. 26 inaccordance with the present disclosure;

FIG. 34 is a photograph of an example patterned apertured web producedusing the overbond pattern of FIG. 31 and having been subjected to a 45%cross directional stretch using the equipment illustrated in FIG. 26 inaccordance with the present disclosure;

FIG. 35 is a photograph of an example patterned apertured web producedusing the overbond pattern of FIG. 31 and having been subjected to a 55%cross directional stretch using the equipment illustrated in FIG. 26 inaccordance with the present disclosure;

FIG. 36 is a plan view of an example disposable absorbent article havingportions cut away to reveal underlying structure that may comprise oneor more patterned apertured webs, the inner surface of the absorbentarticle is facing the viewer, in accordance with the present disclosure;

FIG. 37 is a top view of an example absorbent core of an absorbentarticle with some layers partially removed, wherein the absorbent corecomprises one or more channels in accordance with the presentdisclosure;

FIG. 38 is a cross-sectional view of the absorbent core taken about line38-38 of FIG. 37 in accordance with the present disclosure;

FIG. 39 is a cross-sectional view of the absorbent core taken about line39-39 of FIG. 37 in accordance with the present disclosure;

FIG. 40 is a top view of an absorbent article of the present disclosure,having portions cut away to reveal underlying structure, that is asanitary napkin in accordance with the present disclosure;

FIG. 41 is a top view of a patterned adhesive applied to a substrate inaccordance with the present disclosure;

FIG. 42 is a top view of another patterned adhesive applied to asubstrate in accordance with the present disclosure;

FIGS. 43-52 represent schematic illustrations of patterned apertures andland area in various patterned apertured webs, with the apertures beingthe black portions and the land areas being the white portions, inaccordance with the present disclosure;

FIG. 53 represents a schematic illustration of an example overbondpattern having overbonds with central longitudinal axes that aresubstantially parallel to a machine direction in accordance with thepresent disclosure;

FIG. 53A is a photograph of a patterned apertured web produced using anoverbond roll having the overbond pattern of FIG. 53 in according withthe present disclosure;

FIG. 54 is a photograph of a portion of a patterned apertured webcomprising fused or melted portions surrounding the apertures inaccordance with the present disclosure;

FIGS. 55-60 illustrate schematic illustrations of example overbondroller patterns used to create patterns of overbonds in webs inaccordance with the present disclosure;

FIG. 61 is a schematic illustration of a patterned apertured web withone of the layers being pre-strained prior to being joined to at leastone of the other layers in accordance with the present disclosure;

FIG. 62 is a photograph of a portion of a patterned apertured web withat least one of the layers being pre-strained prior to being joined toat least one of the other layers in accordance with the presentdisclosure;

FIG. 63 is a cross-sectional view of a patterned apertured web with atleast one of the layers being pre-strained prior to being joined to atleast one of the other layers in accordance with the present disclosure;

FIG. 64 is a photograph of an overbonded web free of any pre-strainedlayers in accordance with the present disclosure;

FIG. 65 is a photograph of the overbonded web of FIG. 64 with apre-strained layer in accordance with the present disclosure;

FIG. 66 is a photograph of an overbonded web free of any pre-strainedlayers in accordance with the present disclosure;

FIG. 67 is a photograph of the overbonded web of FIG. 66 with apre-strained layer in accordance with the present disclosure;

FIG. 68 is a photograph of a patterned apertured web free of anypre-strained layers in accordance with the present disclosure;

FIG. 69 is a photograph of the patterned apertured web of FIG. 68 with apre-strained layer in accordance with the present disclosure;

FIG. 70 is a photograph of a patterned apertured web free of anypre-strained layers in accordance with the present disclosure;

FIG. 71 is a photograph of the patterned apertured web of FIG. 70 with apre-strained layer in accordance with the present disclosure;

FIGS. 72-75 are schematic representations of layers of various webs inaccordance with the present disclosure;

FIGS. 76-79 are plan views of absorbent articles, garment-facingsurfaces facing the viewer, in accordance with the present disclosure;

FIGS. 80 and 81 are photographs of webs with only some of the overbondsruptured to form apertures in accordance with the present disclosure;

FIG. 82 is a photograph of a patterned apertured web for a femininehygiene product, wherein outer portions of the web have embossed areasin accordance with the present disclosure;

FIG. 83 is a photograph of an example patterned apertured web inaccordance with the present disclosure;

FIG. 84 is a photograph of an example moiré effect laminate with a firstlayer in a first position relative to a second layer, wherein a firstportion of a second pattern of the second layer is at least partiallyvisible through a first portion of a first pattern of the first layer,in accordance with the present disclosure;

FIG. 85 is a photograph of the example moiré effect laminate of FIG. 84with the first layer in a second position relative to the second layer,wherein a second portion of the second pattern is at least partiallyvisible through a second portion of the first pattern, in accordancewith the present disclosure;

FIG. 86 is a photograph of the example moiré effect laminate of FIG. 84with the first layer in a third position relative to the second layer,wherein a third portion of the second pattern is at least partiallyvisible through a third portion of the first pattern, in accordance withthe present disclosure;

FIG. 87 is a photograph of the example moiré effect laminate of FIG. 84with the first layer in a fourth position relative to the second layer,wherein a fourth portion of the second pattern is at least partiallyvisible through a fourth portion of the first pattern, in accordancewith the present disclosure;

FIGS. 88-90 are example absorbent articles with bonds or joinedportions, garment-facing surfaces removed to show the position of thebond or joined portions, in accordance with the present disclosure;

FIG. 91 is an example illustration of a moiré effect laminate or otherlaminate of the present disclosure with a first layer having a differentpath length of a second layer, in accordance with the presentdisclosure;

FIG. 92 is an example of a first layer having a first pattern of a moiréeffect laminate, in accordance with the present disclosure;

FIG. 93 is an example of a second layer having a second pattern of moiréeffect laminate, in accordance with the present disclosure;

FIG. 94 is an example the first layer of FIG. 92 overlaid on the secondlayer of FIG. 93 to form a moiré effect laminate, wherein the firstlayer is in a first position relative to the second layer, in accordancewith the present disclosure;

FIG. 95 is an example the first layer of FIG. 92 overlaid on the secondlayer of FIG. 93 to form a moiré effect laminate, wherein the firstlayer is in a second position relative to the second layer, inaccordance with the present disclosure;

FIG. 96 is an example of a first layer having a first pattern of a moiréeffect laminate, in accordance with the present disclosure;

FIG. 97 is an example of a second layer having a second pattern of moiréeffect laminate, in accordance with the present disclosure;

FIG. 98 is an example the first layer of FIG. 96 overlaid on the secondlayer of FIG. 97 to form a moiré effect laminate, wherein the firstlayer is in a first position relative to the second layer, in accordancewith the present disclosure;

FIG. 99 is an example the first layer of FIG. 96 overlaid on the secondlayer of FIG. 97 to form a moiré effect laminate, wherein the firstlayer is in a second position relative to the second layer, inaccordance with the present disclosure;

FIG. 100 is a cross-sectional illustration of a portion of a non-joinedspan of a moiré effect laminate, wherein a first layer is in a firstposition relative to a second layer, and wherein a first portion of asecond pattern of the second layer is visible through a first pattern ofthe first layer, in accordance with the present disclosure;

FIG. 101 is a cross-sectional illustration of a portion of a non-joinedspan of the moiré effect laminate of FIG. 100, wherein the first layerhas been moved into a second position relative to the second layer, andwherein a second portion of the second pattern is visible through thefirst pattern, in accordance with the present disclosure;

FIG. 102 is a cross-sectional illustrate of a portion of a non-joinedspan of a moiré effect laminate, wherein a first layer is in a firstposition relative to a second layer, and wherein a first portion of asecond pattern of the second layer is visible through a first pattern ofthe first layer, in accordance with the present disclosure;

FIG. 103 is a cross-sectional illustration of the portion of thenon-joined span of the moiré effect laminate of FIG. 102, wherein thefirst layer has been moved into a second position relative to the secondlayer, and wherein a second portion of the second pattern is visiblethrough the first patter, in accordance with the present disclosure;

FIGS. 104-107 illustrate patterned apertured webs on an absorbentarticle that have various zones, in accordance with the presentdisclosure; and

FIG. 108 is a side view of a package of absorbent articles in accordancewith the present disclosure. The outer surface is illustrated astransparent for purposes of clarity.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the pre-strained laminatesand methods for making the same disclosed herein. One or more examplesof these non-limiting forms are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thepre-strained laminates and methods of making the same specificallydescribed herein and illustrated in the accompanying drawings arenon-limiting example forms and that the scope of the variousnon-limiting forms of the present disclosure are defined solely by theclaims. The features illustrated or described in connection with onenon-limiting form may be combined with the features of othernon-limiting forms. Such modifications and variations are intended to beincluded within the scope of the present disclosure.

As used herein, the terms “nonwoven material”, “nonwoven”, or “nonwovenlayer” are used in their normal sense and specifically, refers to a webthat has a structure of individual fibers or threads which areinterlaid, but not in any regular, repeating manner. Nonwoven materials,nonwovens, or nonwoven layers have been, in the past, formed by avariety of processes, such as, for example, meltblowing processes,spunbonding processes and bonded carded web processes.

As used herein, the term “microfibers”, refers to small diameter fibershaving an average diameter not greater than about 100 microns.

As used herein, the term “nanofibers”, refers to very small diameterfibers having an average diameter less than about 1 micron.

As used herein, the term “meltblown”, refers to fibers formed byextruding a molten thermoplastic material through a plurality of fine,usually circular, die capillaries as molten threads or filaments into ahigh velocity gas (e.g., air) stream which attenuates the filaments ofmolten thermoplastic material to reduce their diameter, which may be toa microfiber diameter. Thereafter, the meltblown fibers are carded bythe high velocity gas stream and are deposited on a collecting surfaceto form a web of randomly dispersed meltblown fibers.

As used herein, the term “spunbond”, refers to small diameter fiberswhich are formed by extruding a molten thermoplastic material asfilaments from a plurality of fine, usually circular, capillaries of aspinneret with the diameter of the extruded filaments then being rapidlyreduced as by, for example, eductive drawing or other well-knownspunbonding mechanisms.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as, for example, block,graft, random, and alternating copolymers, terpolymer, etc., and blendsand modifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the material. These configurations include, but arenot limited to, isotactic, syndiaotactic and random symmetries.

As used herein, the terms “join”, “joined”, “joining”, “bond”, “bonded”,“bonding”, “attach”, “attached”, or “attaching” encompass configurationswhereby an element is directly secured to another element by affixingthe element directly to the other element, and configurations whereby anelement is indirectly secured to another element by affixing the elementto intermediate member(s) which in turn are affixed to the otherelement.

As used herein, the term “elastic” refers to any material that, uponapplication of a biasing force, can stretch to an elongated length of atleast about 110% of its relaxed, original length (i.e., can stretch to10 percent), without rupture or breakage, and upon release of theapplied force, recovers at least about 40% of its elongation. Forexample, a material that has an initial length of 100 mm can extend atleast to 110 mm, and upon removal of the force would retract to a lengthof 106 mm (40% recovery). “Elastic” may refer to a single material, orit may refer to a combination of materials making up a laminate in anarticle. An elastic material may be incorporated into a laminate whichis not elastic, or which is less elastic than one or more of the elasticmaterials of the laminate.

As used herein, the term “nonelastic” refers to any material which doesnot fall within the definition of “elastic” above.

As used herein, the term “extensible” refers to any material which, uponapplication of a biasing force, is elongatable, at least about 10%, atleast about 20%, at least about 30%, at least about 50%, withoutexperiencing catastrophic failure. Recovery of the elongation is notrequired, but may at least partially occur.

As used herein, the term “melt-stabilized” refers to portions of anonwoven material which have been subjected to localized heating and/orlocalized pressure to substantially consolidate the fibers of thenonwoven material into a stabilized film-like form.

As used herein, the term “absorbent article”, refers to devices whichabsorb and contain bodily exudates (e.g., BM, urine, blood), and, morespecifically, refers to devices which are placed against or in proximityto the body of the wearer to absorb and contain the various bodilyexudates discharged from the body. The term absorbent article includes,but is not limited to, diapers, pants, training pants, adultincontinence products, sanitary napkins, tampons, wipes, and liners. Theterm “absorbent article” may also encompass cleaning or dusting pads orsubstrates that have some absorbency.

The term “machine direction” (MD) is used herein to refer to the primarydirection of material, strip of substrate, or article flow through aprocess.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

As used herein, the term “aperture aspect ratio” is the ratio of themajor axis to the minor axis of a single aperture.

As used herein, the term “pre-strain” or “pre-strained” means a materialthat has been elongated to at least 105% of one of its original (i.e.,before being strained) dimensions and then is capable of at leastpartial recovery after the elongating force is removed.

Patterned Apertured Webs

The patterned apertured webs of the present disclosure provide manybenefits over conventional apertured topsheets, as will be describedherein. Four examples of patterned apertured webs 10 are illustrated inFIGS. 1-4. As illustrated, the patterned apertured webs 10 may take on anumber of configurations. The apertures are labeled 12 and the landareas (non-apertured areas) are labeled 14. Additional examples ofpatterned apertured webs are illustrated in subsequent figures. Some ofthe patterned apertured webs may have land area widths of at least about4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, atleast about 8 mm, at least about 9 mm, at least about 10 mm, or in therange of about 4 mm to about 15 mm, specifically reciting all 0.1 mmincrements within the specified range and all ranges formed therein.These land area widths may be measured using a NIST traceable/certifiedruler from a perimeter of one aperture to a perimeter of anotheraperture in any direction. As an example, FIG. 2 illustrates discreteaperture patterns (e.g., set apart from other aperture patterns).

Layers

The patterned apertured webs of the present disclosure may comprise asingle apertured layer (see FIGS. 1-4) or more than one layer (aperturedor non-apertured), for example, two, three, or four layers. The term“layer” means a self-sustaining web (e.g., a nonwoven or a film) and nota non-self-sustaining web (e.g., a spunbond layer of an SMMS nonwoven).Thus, a Spunbond-Meltblown-Meltblown-Spunbond (SMMS) nonwoven materialwould be considered a single layer for purposes of this disclosure, muchlike a film would be considered a single layer. The patterned aperturedwebs may comprise one or more non-apertured layers that have not beenput through an aperturing process, but merely have pores (that are notapertures for purposes of this disclosure) created in the formation ofthe material. If two apertured layers are provided in a patternedapertured web, each layer may have the same aperturing pattern or adifferent aperturing pattern.

Referring to FIG. 5, a schematic illustration of an examplecross-sectional view of a patterned apertured web 10 comprising twolayers is illustrated. Although the examples of the patterned aperturedwebs of FIG. 5-10 comprise more than one layer, patterned apertured websof the present disclosure may only have one layer (see, for example,FIGS. 1-4). The patterned apertured web 10 may comprise a patternedapertured layer 16 and a non-apertured layer 18. The patterned aperturedlayer 16 may comprise any of the various aperture patterns disclosedherein, for example. The patterned aperture layer 16 may be combinedwith, bonded to, adhesively joined to, or joined to the non-aperturedlayer 18 to form a laminate. The patterned apertured layer 16 may haveapertures and land areas at least partially, or fully, surrounding theapertures.

If both or all layers of a multi-layer patterned apertured web areapertured, the apertures may be aligned or overlapping, not aligned ornot overlapping, or partially aligned or partially overlapping in theZ-direction. For instance, the apertures in one layer may be 100%aligned or overlapping in the Z-direction with the apertures in a secondlayer thus forming apertures through both layers of the patternedapertured web. In such an instance, the apertures may be formed byoverbonding both layers together to join the layers and then rupturingthe overbonds to form apertures in both of the layers (or more than twoof the layers). In other instances, the apertures may be less than 100%aligned or overlapping in the Z-direction. Stated another way, theapertures in one layer may be offset in the CD, MD, or other directionor different patterns of apertures may be formed in each layer to createthe misalignment of the apertures. In such instances, the area of theapertures in one layer may overlap the area of the apertures in anotherlayer, in the Z-direction, by 10% to 90%, 10% to 100%, 10% to 80%, 25%to 75%, 25%, 50%, or 75%, for example, specifically reciting all 0.5%increments within the specified ranges and all ranges formed therein orthereby.

In instances where more than one layer of a patterned apertured webincludes apertures, the apertures may be coincident in the Z-direction,i.e., penetrate through both layers. In a form, this may be achieved byforming the apertures after bonding, joining and/or laminating the twoor more layers together. Alternatively, the apertures in one layer mayhave a different pattern, size, and/or shape from the apertures in asecond layer and/or may be oriented in a different direction. In a form,this may be achieved by forming the apertures in each of the layersprior to combining the two or layers into a laminated structure. Inabsorbent article forms comprising a patterned apertured web having anapertured layer and a non-apertured layer, the apertured layer may beoriented on the wearer-facing side of the patterned apertured web or onthe garment-facing side of the patterned apertured web. In still otherforms, the patterned apertured layer may be positioned intermediate twonon-apertured layers or may be positioned under one or morenon-apertured layers. In yet another form, two patterned aperturedlayers may sandwich one or more non-apertured layers in a patternedapertured web.

A first layer of a patterned apertured web may have the same or adifferent hydrophilicity as another layer of the same patternedapertured web. Both layers may be hydrophilic or hydrophobic, but onemay be more hydrophilic or hydrophobic. As an example, a wearer-facinglayer of a patterned apertured web may be hydrophobic while agarment-facing layer of the patterned apertured web may be hydrophilicto help wick fluid into the apertures and into an absorbent core. Asanother example, a first layer of a patterned apertured web may be ahydrophobic topsheet with apertures and a second layer of a patternedapertured web may be hydrophilic acquisition layer or material. This canpromote fluid wicking or drainage into the absorbent core and providedepth perception.

In an instance, again referring to FIG. 5, the patterned apertured layer16 may have a different color as the non-apertured layer 18, such thatthe apertures in the layer 16 are easily visible or more readilyapparent to a user. The aperture pattern in the patterned aperturedlayer 16 may also form indicia that may indicate the correct orientationof an absorbent article comprising the patterned apertured web 10 on awearer. Such indicia may include any object or shape that has a commonlyunderstood vertical orientation, such as a heart shape, a face, abuilding, a letter or numeral, a car, for example. This may also applyto other patterned apertured webs described herein, regardless of howmany apertured or non-apertured layers are provided.

Any of the patterned apertured webs described herein may have gradientsof color to indicate which side of the product comprising the web is thetop and which side is the bottom or to indicate depth in an absorbentarticle or to provide an enhanced depth perception.

The layers of the patterned apertured webs of the present disclosure mayhave the same basis weights or different basis weights. In an instance,again referring to FIG. 5, the layer 16 may have a higher basis weightthan the layer 18. This may provide better softness on a surface of thelayer 16 (e.g., a topsheet contacting a baby's skin), while alsoproviding enhanced fluid penetration owing to the apertures in the layer16. The various layers of the patterned apertured webs of the presentdisclosure may also be the same or different in material compositions,density, caliper, opacity, lotion concentration, or any other propertiesof nonwoven materials.

The basis weight of a patterned apertured web, or a layer thereof, mayin the range of about 6 gsm to about 200 gsm, about 10 gsm to about 100gsm, about 10 gsm to about 50 gsm, or about 10 gsm to about 40 gsm,specifically reciting all 0.1 gsm increments within the above-specifiedrange and all ranged formed therein or thereby. Basis weight is measuredaccording to the Basis Weight Test herein.

The predominant fiber orientation of the fibers in the layers of themulti-layer patterned apertured webs may be the same or different. In aninstance, a predominant fiber orientation may be about 45 degrees toabout 135 degrees, for example, off-axis relative to a machinedirection, while another layer may have a predominant fiber orientationsubstantially along a machine direction or +/−about 10 to about 20degrees from the machine direction. Providing different layers in apatterned apertured web with different predominant fiber orientationsmay provide increased strength and resistance to tearing of thepatterned apertured web when the two or more layers are joined or bondedtogether.

Referring to FIG. 6, a schematic illustration of an examplecross-sectional view of another patterned apertured web 10 isillustrated. The patterned apertured web 10 may comprise a firstpatterned apertured layer 20 and a second patterned apertured layer 22.Apertures of the first patterned apertured layer 20 in FIG. 6 may beabout 80%, about 85%, about 90%, about 95%, about 80% to about 100%, orabout 100% aligned, in the Z-direction (indicated by arrow Z), withapertures in the second patterned apertured layer 22, specificallyreciting all 0.5% increments within the specified range and all rangesformed therein. The first patterned apertured layer 20 may be combinedwith, bonded to, or joined to the second patterned aperture layer 22 toform a laminated patterned apertured web. The patterned apertured web 10of FIG. 6, or any of the other patterned apertured webs of the presentdisclosure, may comprise a third layer 21 (or more than three layers)that may be non-apertured or apertured. The second patterned aperturedlayer 22 may be combined with, bonded to, or joined to the thirdnon-apertured layer 21.

Again referring to FIG. 6, the apertures in the second patternedapertured layer 22 may be smaller than (e.g., about 10% less area, about20% less area, about 30% less area etc.) the apertures in the firstpatterned apertured layer 20. Such a feature may allow BM penetrationthrough the first layer 20 while also providing adequate liquid bodilyexudate (e.g., urine and menses) fluid strikethrough through the secondlayer 22 or rewet from the first layer compared to a non-aperturedsecond layer.

Referring to FIG. 7, a schematic illustration of an examplecross-sectional view of another patterned apertured web 10 isillustrated. The patterned apertured web 10 may comprise a firstpatterned apertured layer 24 and a second patterned apertured layer 26.Apertures of the first patterned apertured layer 24 may be fullyoverlapped by non-apertured portions or “land areas” of the secondpatterned apertured layer 26 in the Z-direction (indicated by arrow Z).The first patterned apertured layer 24 may be combined with, bonded to,or joined to the second patterned aperture layer 26 to form a laminatedpatterned apertured web.

Referring to FIG. 8, a schematic illustration of an examplecross-sectional view of another patterned apertured web 10 isillustrated. The patterned apertured web 10 may comprise a firstpatterned apertured layer 28 and a second patterned apertured layer 30.Apertures of the first patterned apertured layer 28 may be partiallyoverlapped by non-apertured portions or “land areas” of the secondpatterned apertured layer 30 in the Z-direction (indicated by arrow Z).The first patterned apertured layer 28 may be combined with, bonded to,or joined to the second patterned aperture layer 30 to form a laminatedpatterned apertured web. The overlap of the areas of the apertures inthe first patterned apertured layer 28 and the areas of the apertures inthe second patterned apertured layer may be in the range of about 5% toabout 95%, about 10% to about 90%, about 20% to about 80%, about 25% toabout 75%, about 25%, about 50%, or about 75%, specifically reciting all0.5% increments within the specified ranges and all ranges formedtherein or thereby.

The example patterned apertured web 10 of FIG. 8 may also comprise apigmented substance (full continuous layer) or a patterned pigmentedsubstance 29 at least partially intermediate the first and secondpatterned apertured layers 28 and 30. This concept may also apply to anyof the examples in FIGS. 5-10 or other examples herein. The pigmentedsubstance may also be positioned on either of the layers 28 and 30. Thepigmented substance or patterned pigmented substance 29 may comprisegraphics, inks, pigmented adhesives or other pigmented substances andmay be viewable through the overlapping areas of the apertures fromeither side of the patterned apertured web 10. In a form, the pigmentedsubstance or patterned pigmented substance 29 may be positioned underthe second patterned apertured layer 30 and may still be viewablethrough the overlapping areas of the apertures when viewing from thefirst patterned apertured layer 28. The first patterned apertured layer28, the second patterned apertured layer 30, and the pigmented substanceor the patterned pigmented substance 29 may be the same color or mayeach be a different color. Alternatively, the patterned apertured layers28 and 30 may have a different color as the pigmented substance or thepatterned pigmented substance 29. Such forms allow for athree-dimensional appearance to be provided in the patterned aperturedweb 10 without actually making the patterned apertured web 10three-dimensional, such as through embossing, for example.

Materials

Any of the layers of the patterned apertured webs described herein maycomprise any materials known in the art including, but not limited to,nonwovens, wovens, cellulosic materials, films, elastic materials,non-elastic materials, highloft materials, and/or foams. The patternedapertured webs may also comprise one or more layers of one or morenonwoven materials, one or more films, combinations of differentnonwoven materials, combinations of different films, combinations of oneor more films and one or more nonwoven materials, or combinations of oneor more different materials, for example. Patterned apertured webshaving one or more layers of the same or similar materials are alsowithin the scope of the present disclosure. The basis weight, color,opacity, hydrophilicity, Average Interaperture Distance, AverageAbsolute Feret Angle, Effective Aperture Area, Effective Open Area, orother parameters or characteristics of the various materials in thevarious layers may be the same or different.

Some precursor web materials for the patterned apertured webs maycomprise PE/PP bicomponent fiber spunbond webs. Other suitable precursorwebs may comprise spunbond webs comprising side-by-side crimped fibers(e.g., PE/PP or PP/PP) that are bonded via calendar (thermal point)bonding or through-air bonding. Other suitable precursor webs maycomprise carded, through-air bonded or resin bonded (highloft) nonwovenscomprising PE/PP or PE/PET fibers. The precursor webs may comprisemicrofibers and/or nanofibers, optionally with other fibers. In somecircumstances, multiple layer webs may be desired over a single layerwebs (even at the same basis weight) due to increased uniformity/opacityand the ability to combine webs having different properties. Forexample, an extensible spunbond nonwoven carrier layer may be combinedwith a soft, highloft nonwoven (spunbond or carded) to create anapertured web that is both soft and strong. The layers may have the sameor different surface energy. For example, the top layer may behydrophobic and the lower layer may be hydrophilic. The layers may havedifferent permeability/capillarity, e.g. the upper layer may have higherpermeability and the lower layer have higher capillarity in order to setup a capillary gradient and aid in moving fluid away from the surface(or topsheet) of an absorbent article and into an absorbent core of theabsorbent article. Fibers of the precursor web materials may compriseany suitable thermoplastic polymers.

Example thermoplastic polymers are polymers that melt and then, uponcooling, crystallize or harden, but that may be re-melted upon furtherheating. Suitable thermoplastic polymers may have a melting temperature(also referred to as solidification temperature) from about 60° C. toabout 300° C., from about 80° C. to about 250° C., or from about 100° C.to about 215° C., specifically reciting all 0.5° C. increments withinthe specified ranges and all ranges formed therein or thereby. And, themolecular weight of the thermoplastic polymer may be sufficiently highto enable entanglement between polymer molecules and yet low enough tobe melt spinnable.

The thermoplastic polymers may be derived from any suitable materialincluding renewable resources (including bio-based and recycledmaterials), fossil minerals and oils, and/or biodegradeable materials.Some suitable examples of thermoplastic polymers include polyolefins,polyesters, polyamides, copolymers thereof, and combinations thereof.Some example polyolefins include polyethylene or copolymers thereof,including low density, high density, linear low density, or ultra-lowdensity polyethylenes such that the polyethylene density ranges betweenabout 0.90 grams per cubic centimeter to about 0.97 grams per cubiccentimeter or between about 0.92 and about 0.95 grams per cubiccentimeter, for example. The density of the polyethylene may bedetermined by the amount and type of branching and depends on thepolymerization technology and co-monomer type. Polypropylene and/orpolypropylene copolymers, including atactic polypropylene; isotacticpolypropylene, syndiotactic polypropylene, and combination thereof mayalso be used. Polypropylene copolymers, especially ethylene may be usedto lower the melting temperature and improve properties. Thesepolypropylene polymers may be produced using metallocene andZiegler-Natta catalyst systems. These polypropylene and polyethylenecompositions may be combined together to optimize end-use properties.Polybutylene is also a useful polyolefin and may be used in some forms.Other suitable polymers include polyamides or copolymers thereof, suchas Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon 66; polyesters orcopolymers thereof, such as maleic anhydride polypropylene copolymer,polyethylene terephthalate; olefin carboxylic acid copolymers such asethylene/acrylic acid copolymer, ethylene/maleic acid copolymer,ethylene/methacrylic acid copolymer, ethylene/vinyl acetate copolymersor combinations thereof; polyacrylates, polymethacrylates, and theircopolymers such as poly(methyl methacrylates).

The thermoplastic polymer component may be a single polymer species or ablend of two or more thermoplastic polymers e.g., two differentpolypropylene resins. As an example, fibers of a first nonwoven layer ofa patterned apertured web may comprise polymers such as polypropyleneand blends of polypropylene and polyethylene, while a second nonwovenlayer of the patterned apertured web may comprise fibers selected frompolypropylene, polypropylene/polyethylene blends, andpolyethylene/polyethylene terephthalate blends. In some forms, thesecond nonwoven layer may comprise fibers selected from cellulose rayon,cotton, other hydrophilic fiber materials, or combinations thereof. Thefibers may also comprise a super absorbent material such as polyacrylateor any combination of suitable materials.

The fibers of the layer of the patterned apertured web may comprisemonocomponent fibers, bi-component fibers, and/or bi-constituent fibers,round fibers or non-round fibers (e.g., capillary channel fibers), andmay have major cross-sectional dimensions (e.g., diameter for roundfibers) ranging from about 0.1 microns to about 500 microns. The fibersmay also be a mixture of different fiber types, differing in suchfeatures as chemistry (e.g. polyethylene and polypropylene), components(mono- and bi-), denier (micro denier and >2 denier), shape (i.e.capillary and round) and the like. The fibers may range from about 0.1denier to about 100 denier.

Example materials are contemplated where a first plurality of fibersand/or a second plurality of fibers comprise additives in addition totheir constituent chemistry. For example, suitable additives includeadditives for coloration, antistatic properties, lubrication, softness,hydrophilicity, hydrophobicity, and the like, and combinations thereof.These additives, for example titanium dioxide for coloration, maygenerally be present in an amount less than about 5 weight percent andmore typically less than about 2 weight percent or less.

As used herein, the term “monocomponent fiber(s)” refers to a fiberformed from one extruder using one or more polymers. This is not meantto exclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc.

As used herein, the term “bi-component fiber(s)” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bi-componentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebi-component fibers and extend continuously along the length of thebi-component fibers. The configuration of such a bi-component fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement. Some specificexamples of fibers which may be used in the first nonwoven layer includepolyethylene/polypropylene side-by-side bi-component fibers. Anotherexample is a polypropylene/polyethylene bi-component fiber where thepolyethylene is configured as a sheath and the polypropylene isconfigured as a core within the sheath. Still another example is apolypropylene/polypropylene bi-component fiber where two differentpropylene polymers are configured in a side-by-side configuration.Additionally, forms are contemplated where the fibers of a nonwovenlayer are crimped.

Bi-component fibers may comprise two different resins, e.g. a firstpolypropylene resin and a second polypropylene resin. The resins mayhave different melt flow rates, molecular weights, or molecular weightdistributions. Ratios of the 2 different polymers may be about 50/50,60/40, 70/30, 80/20, or any ratio within these ratios. The ratio may beselected to control the amount of crimp, strength of the nonwoven layer,softness, bonding or, the like.

As used herein, the term “bi-constituent fiber(s)” refers to fiberswhich have been formed from at least two polymers extruded from the sameextruder as a blend. Bi-constituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross-sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Bi-constituent fibers are sometimes also referred to asmulti-constituent fibers. In other examples, a bi-component fiber maycomprise multiconstituent components.

As used herein, the term “non-round fiber(s)” describes fibers having anon-round cross-section, and includes “shaped fibers” and “capillarychannel fibers.” Such fibers may be solid or hollow, and they may betri-lobal, delta-shaped, and may be fibers having capillary channels ontheir outer surfaces. The capillary channels may be of variouscross-sectional shapes such as “U-shaped”, “H-shaped”, “C-shaped” and“V-shaped”. One practical capillary channel fiber is T-401, designatedas 4DG fiber available from Fiber Innovation Technologies, Johnson City,Tenn. T-401 fiber is a polyethylene terephthalate (PET polyester).

Other example nonwoven materials for the patterned apertured webs maycomprise spunbond materials, carded materials, melt blown materials,spunlace materials, needle punched materials, wet-laid materials, orair-laid materials, for example.

Some other example materials for at least one layer of the patternedapertured webs of the present disclosure are those that are capable ofelongation in the cross-machine direction of greater than about 100%,greater than about 120%, or greater than about 150%. This enables theweb to extend upon stretching and minimizes the number of broken fibersand/or tears between apertures. One example of this type of web is aspunbond web comprising sheath/core bicomponent fibers of polyethylenein the sheath and polypropylene in the core. An example may be a 25 gsmnonwoven comprising fibers that are 2.8 denier per filament with a 50/50polyethylene/polypropylene ratio available from Fitesa in Washougal,Wash.

It may be desirable for individual precursor materials, or at least oneof the layer within a patterned apertured web, to be capable ofundergoing an elongation of greater than or equal to about one of thefollowing amounts: about 100% (that is double its unstretched length),about 110%, about 120%, or about 130% up to about 200%, or more, at orbefore reaching the peak tensile force. It may also desirable for theprecursor materials to be capable of undergoing plastic deformation toensure that the structure of the deformations is “set” in place so thatthe nonwoven laminate will not tend to recover or return to its priorconfiguration. However, in the case crimped fiber spunbond layers, itmay be desirable for the precursor material for these specific layer(s)to be capable of experiencing no or minimal plastic deformation duringprocessing.

In contrast to spunbond nonwoven layers, the constituent fibers of thecrimped fiber spunbond nonwoven layers typically are uncoiled and/ordisplaced when processed. Because the crimped fibers tend to coil tosome extent, the processing typically displaces/uncoils the crimpedfibers as opposed to elongating the crimped fibers.

Extensibility of a nonwoven layer may be impacted by bonding betweenconstituent fibers. This is true for both spunbond nonwoven layer andcrimped fiber spunbond nonwoven layers. For example, to increaseextensibility in a nonwoven layer, it may be desirable for the nonwovenlayer to be underbonded as opposed to optimally bonded prior toprocessing. A thermally bonded nonwoven web's tensile properties may bemodified by changing the bonding temperature. A web may be optimally orideally bonded, underbonded or overbonded. Optimally or ideally bondedwebs are characterized by the highest peak tensile strength andelongation at tensile peak with a rapid decay in strength after tensilepeak. Under strain, bond sites fail and a small amount of fibers pullout of the bond site. Thus, in an optimally bonded nonwoven, the fibersmay stretch and break around the bond sites when the nonwoven web isstrained beyond a certain point. Often there is a small reduction infiber diameter in the area surrounding the thermal point bond sites.Underbonded webs have a lower peak tensile strength and elongation attensile peak when compared to optimally bonded webs, with a slow decayin strength after tensile peak. Under strain, some fibers will pull outfrom the thermal point bond sites. Thus, in an underbonded nonwoven, atleast some of the fibers can be separated easily from the bond sites toallow the fibers to pull out of the bond sites and rearrange when thematerial is strained. Overbonded webs also have a lowered peak tensilestrength and elongation at tensile peak when compared to optimallybonded webs, with a rapid decay in strength after tensile peak. The bondsites look like films and result in complete bond site failure understrain.

Joining of Layers

If more than one layer is provided in a particular patterned aperturedweb, the layers may be bonded together using any bonding methods knownto those of skill in the art, such as adhesive bonding, patternedadhesive coating, ultrasonic bonding, thermal bonding, mechanicalbonding, or any combination of these bonding methods. Alternatively, thevarious layers may be bonded together only at the perimeter of theapertures, or partially the perimeter of the apertures, through anoverbonding process. The bonding may be done in a pattern of bonds or inarrays of bonds. The pattern may be a regular, homogeneous and uniformpattern or an irregular, non-uniform and non-homogeneous pattern. Thebonding patterns may comprise a substantially continuous bond pattern ormay be formed of discrete bonding points. The discrete bonding pointsmay form a pattern. The pattern of bonding points may be homogeneous ornon-homogeneous. A bond pattern in one region of a patterned aperturedweb may differ from a bond pattern in another region of the patternedapertured web. For example, the bond pattern may be different in themachine direction or the cross-machine direction of the patternedapertured web laminate. An absorbent article including the patternedapertured web may have a different bond pattern in the front region vs.the back region, the center region vs. side regions, the crotch regionvs. waist regions, or a first portion and a second portion of a topsheetor an outer cover, of the absorbent article, for example. Bonding inpatterned apertured webs is typically accomplished by joining the landareas of various layers of the patterned apertured webs. If an adhesiveis used in the bonding process, the adhesive may be tinted, pigmented,and/or patterned to create a complementary or contrasting patterncompared to the aperture pattern or patterns.

Color/Printing/Adhesives

Any of the layers of the patterned apertured webs may have a color thatis the same or different than another layer of the patterned aperturedweb, regardless of whether a layer is apertured or non-apertured. Forinstance, in a two layer patterned apertured web, a first layer may beblue and a second layer may be white, or a first layer may be dark blueand the second layer may be light blue. There may be a Delta Edifference between at least some of the layers. The layers may also havethe same opacity or a different opacity, as described in further detailbelow. Single layer patterned apertured webs may also have a color.

Either in addition to or in lieu of the various layered being colored,referring to FIG. 9, one or more of the layers of the patternedapertured webs 10 of the present disclosure may comprise printing 32,e.g., with ink or a pigmented or colored pattern. Single layer patternedapertured webs may also comprise ink or a pigmented or colored pattern.The ink may be deposited via any printing process known in the artincluding, but not limited to, flexographic printing and digital inkjetprinting. The printing may form graphics or other indicia. The printingmay be on an external surface of a first layer 34 of the patternedapertured web 10, between the first and second layers 34, 36 (asillustrated) of the patterned apertured web 10, or may be on a surfacebeneath the second layer 36 of the patterned apertured web 10. Theprinting may also be situated in any suitable location if the patternedapertured web has more than two layers (e.g., on the surface of any ofthe layers). The printing may also be deposited in zones of thepatterned apertured web, or layers thereof, and/or in patternsthroughout the patterned apertured web, or layers thereof. The printingmay be different or the same in different zones of the patternedapertured web, or layers thereof. If the printing is covered by one ofthe layers (e.g., layer 34), the covering layer (e.g., layer 34) mayhave a relatively low opacity to enhance the visual appearance of theprinting. The density of the printing (e.g., clarity and contrast) maybe enhanced by including small-denier fibers in the printed layerincluding, but not limited to, melt-blown fibers, microfibers, andnanofibers. In an instance, the printing may indicate the properorientation of an absorbent article on a wearer (e.g., front/rear). Itwill be understood that printing may be used with any of the variousforms and configurations of the patterned apertured webs disclosedherein. In some forms, more than one type or color, for example, ofprinting may be used in a single patterned apertured web, or layerthereof. Additional layers may also be provided in a pattered aperturedweb having one or more prints.

Either in addition to or in lieu of the various layered being coloredand/or having printing, referring to FIG. 10, the patterned aperturedwebs may comprise a pigmented adhesive 38 or other pigmented substance(hereinafter “colored adhesive”). The pigmented adhesive 38 may includea dye, for example. The colored adhesive, in a form, may be positionedbetween a first layer 40 and second layer 42 of a patterned aperturedweb 10. The colored adhesive may be formed in a pattern that correspondswith, coordinates with, matches, or does not correspond with, does notcoordinate with, or does not match the aperture pattern in one or moreaperture layers 40. It will be understood that a pigmented adhesive maybe used with any of the various forms and configurations of thepatterned apertured webs disclosed herein. In some forms, more than onecolored adhesive may be used in a single patterned apertured web. Thepigmented adhesive may also be situated in any suitable location if thepatterned apertured web has more than two layers (e.g., on the surfaceof or intermediate any of the layers). The pigmented adhesive may alsobe deposited in zones of the patterned apertured web, or layers thereof,and/or in patterns throughout the patterned apertured web, or layersthereof. The pigmented adhesive may be different or the same indifferent zones of the patterned apertured web, or layers thereof. Thepigmented adhesive may be positioned intermediate the two layers 40, 42or positioned on any other surfaces of the layers 40, 42. Additionallayers may also be provided in a patterned apertured web having one ormore colored adhesives.

In an instance, a colored adhesive may be positioned between two lowbasis weight materials (e.g., about 15 gsm or less, about 10 gsm orless) forming a patterned apertured web, so that the colored adhesivemay be visible from either side of the patterned apertured web. In atopsheet context, this can provide a high basis weight multilayertopsheet to achieve improved softness, while still retaining the benefitof seeing the colored adhesive from either side of the patternedapertured web.

Example Patterned Apertured Webs

Additional examples of patterned apertured webs 10 are illustrated inFIGS. 11-15.

Opacity

The opacity of at least one of the layers of a patterned apertured webmay differ from the opacity of at least one of the other layers of thepatterned apertured web. Opacity is measured according to the OpacityTest herein. In some instances, the layer of the patterned apertured webclosest to an external observer may have a lower opacity than anunderlying layer in order to maximize observable contrast differencesbetween the layers and/or to observe printing or colored adhesives.Alternatively, the layer of the patterned apertured web closest to anexternal observer may have a higher opacity than an underlying layer inorder to more effectively mask bodily exudates (e.g., urine, menses, orBM) or to provide for greater color contrast with the layers below. Whena patterned apertured web is used as a fluid-permeable topsheet, thelayer closest to an external observer would be the wearer-facingsurface. In a form, where the patterned apertured web is located on theexternal surface of an absorbent article (e.g., an outer cover,fastening system element, stretch ear, wing of a sanitary napkin, belt,or side panel), the layer closest to an external observer would be thegarment-facing surface. For example, the opacity of a non-aperturedlayer may be lower than that of a patterned apertured layer, or viceversa, depending on the specific orientation of a patterned aperturedweb in an absorbent article.

A nonwoven web may have a high opacity. This enables an aperture patternto be more easily distinguished, provides contrast to any colors andmaterials underneath, and in the case of a diaper topsheet or a sanitarynapkin topsheet, masks the presence of bodily fluids contained withinthe absorbent core, providing a cleaner appearance to the wearer. Toachieve this benefit, opacities of about 30%, about 40%, about 50%,about 60%, about 70%, about 80%, about 90%, in the range of about 40% toabout 100%, or about 50% to about 90%, specifically reciting all 0.1%increments within the specified ranges and all ranges formed therein orthereby, may be desired. Increases in opacity may be achieved via anyknown mechanisms including fillers (e.g. TiO2), fiber shape (e.g.Trilobal vs. round), smaller fiber diameters (including microfibersand/or nano fibers), etc. One example of such a web may have an SMSconstruction. Another example is a nonwoven comprising nanofibers, suchas those produced by melt film fibrillation (e.g., U.S. Pat. No.8,487,156 and U.S. Pat. Appl. Publ. Serial No. 2004/0266300).

Components of Absorbent Articles

The patterned apertured webs of the present disclosure may be used ascomponents of absorbent articles. More than one patterned apertured webmay be used in a single absorbent article. In such a context, thepatterned apertured webs may form at least a portion of: a topsheet; atopsheet and an acquisition layer; a portion of a sanitary napkin, awing of a sanitary napkin, a topsheet and a distribution layer; atopsheet, an acquisition layer, and a distribution layer (and any otherlayers intermediate the topsheet and an absorbent core, such as acarrier layer for a distribution layer as disclosed in U.S. patentapplication Ser. No. 14/844,037, filed on Sep. 3, 2015, an acquisitionlayer and a distribution layer; an outer cover; an outer cover and abacksheet, wherein a film (non-apertured layer) of the patternedapertured web forms the backsheet and a nonwoven material forms theouter cover; a leg cuff; an ear or side panel; a fastener; a waist band;a belt, or portion thereof; or any other suitable portion of anabsorbent article. The patterned apertured webs may take on differentconfigurations and patterns of land and aperture areas depending ontheir particular use in an absorbent article on other product. Thenumber of layers in a patterned apertured web may also be determined bythe patterned apertured webs' particular use.

As referenced above, any of the patterned apertured webs of the presentdisclosure may be disposed on an external surface of the absorbentarticle (i.e., the outer cover or garment facing-surface). In such aninstance, the patterned apertures or properties of the same may be thesame or different in different regions of the external surface. In anouter cover example, effective aperture areas and effective open areasmay be higher in a waist region than in a crotch region of the outercover for better breathability. In another outer cover form, the waistregions may include patterned apertures of the present disclosure, whilethe crotch region comprises more uniform aperture patterns or noapertures. In each of these forms, the effective aperture area andeffective open area, or apertures may provide higher air porosity in thewaist region than in the crotch region, allowing more sweat evaporationand better breathability in the tightly occluded waist area

Feminine Hygiene Products

The patterned apertured webs may also be used as components of absorbentarticles, such as feminine hygiene products, including sanitary napkins(or wings thereof), liners, and tampons. More than one patternedapertured web may be used in a single feminine hygiene product. In asanitary napkin context, the patterned apertured webs may form at leasta portion of: a topsheet; a topsheet and an acquisition layer; atopsheet and a distribution layer; a topsheet and a secondary topsheet;an outer cover; an outer cover and a backsheet; wings; wings and atopsheet or a backsheet; an outer covering for a tampon; or any othersuitable portion of a feminine hygiene product. The patterned aperturedwebs may take on different configurations and patterns of land andaperture areas depending on their particular use in a feminine hygieneproduct. The number of layers in a patterned apertured web may also bedetermined by the patterned apertured webs' particular use.

Other Consumer Products

The patterned apertured webs may also be used as components of absorbentarticles, such as cleaning substrates, dusting substrates, and/or wipes.More than one patterned apertured web may be used in a single cleaningor dusting substrate and/or a single wipe. The patterned apertured websmay take on different configurations and patterns of land and apertureareas depending on their particular use in a cleaning substrate, dustingsubstrate, and/or a wipe. The number of layers in a patterned aperturedweb may also be determined by the patterned apertured webs' particularuse.

Physical Characteristics

The patterned apertured webs of the present disclosure may take ondifferent physical characteristics depending on their intended ordesired use in absorbent articles, feminine hygiene products, cleaningsubstrates, dusting substrates, wipes, or other consumer products. Forinstance, the properties of density, basis weight, aperture pattern,land area pattern, caliper, opacity, three-dimensionality, and/orelasticity, for example, may be varied depending on the desired use ofthe patterned apertured web. More than one patterned apertured web maybe combined with other, similar or different, patterned apertured websin some instances for certain design criteria.

Methods of Making

The patterned apertured webs of the present disclosure may be madegenerally by using the process generally described in U.S. Pat. No.5,628,097 entitled “Method for Selectively Aperturing a Nonwoven Web”which issued May 13, 1997 and U.S. Patent Publication 2003/0021951entitled “High Elongation Apertured Nonwoven Web and Method of Making”which published Jan. 20, 2003. This process is described in furtherdetail below. The patterned apertured webs may also be made byhydroforming carded webs, laser cutting, punching with a patterned roll,or other suitable methods.

Referring to FIG. 16 there is schematically illustrated at 100 oneprocess for forming the patterned apertured webs of the presentdisclosure.

First, a precursor material 102 is supplied as the starting material.The precursor material 102 can be supplied as discrete webs, e.g.sheets, patches, etc. of material for batch processing. For commercialprocessing, however, the precursor material 102 may be supplied as rollstock, and, as such it can be considered as having a finite width and aninfinite length. In this context, the length is measured in the machinedirection (MD). Likewise, the width is measured in the cross machinedirection (CD).

The precursor material 102 may be one or more nonwoven materials (sameor different), one or more films (same or different), a combination ofone or more nonwoven materials and one or more films, or any othersuitable materials or combinations thereof. The precursor material 102may be purchased from a supplier and shipped to where the patternedapertured webs are being formed or the precursor material 102 formed atthe same location as where the patterned apertured web are beingproduced.

The precursor material 102 may be extensible, elastic, or nonelastic.Further, the precursor material 102 may be a single layer material or amultilayer material. In an instance, the precursor material 102 may bejoined to a polymeric film to form a laminate.

The precursor material 102 may comprise or be made of mono-component,bi-component, multi-constituent blends, or multi-component fiberscomprising one or more thermoplastic polymers. In an example, thebicomponent fibers of the present disclosure may be formed of apolypropylene core and a polyethylene sheath. Further details regardingbi-component or multi-component fibers and methods of making the samemay be found in U.S. Patent Application Publ. No. 2009/0104831,published on Apr. 23, 2009, U.S. Pat. No. 8,226,625, issued on Jul. 24,2012, U.S. Pat. No. 8,231,595, issued on Jul. 31, 2012, U.S. Pat. No.8,388,594, issued on Mar. 5, 2013, and U.S. Pat. No. 8,226,626, issuedon Jul. 24, 2012. The various fibers may be sheath/core, side-by-side,islands in the sea, or other known configurations of fibers. The fibersmay be round, hollow, or shaped, such as trilobal, ribbon, capillarychannel fibers (e.g., 4DG). The fibers may comprise microfibers ornanofibers.

The precursor material 102 may be unwound from a supply roll 104 andtravel in a direction indicated by the arrow associated therewith as thesupply roll 104 rotates in the direction indicated by the arrowassociated therewith. The precursor material 102 passes through a nip106 of a weakening roller (or overbonding) arrangement 108 formed byrollers 110 and 112, thereby forming a weakened precursor material. Theweakened precursor material 102 has a pattern of overbonds, or densifiedand weakened areas, after passing through the nip. At least some of, orall of, these overbonds are used to form apertures in the precursormaterial 102. Therefore, the overbonds correlate generally to thepatterns of apertures created in the precursor material 102.

Referring to FIG. 17, the precursor material weakening rollerarrangement 108 may comprises a patterned calendar roller 110 and asmooth anvil roller 112. One or both of the patterned calendar roller110 and the smooth anvil roller 112 may be heated and the pressurebetween the two rollers may be adjusted by known techniques to providethe desired temperature, if any, and pressure to concurrently weaken andmelt-stabilize (i.e., overbond) the precursor material 102 at aplurality of locations 202. The temperature of the calendar roller 110(or portions thereof) and/or the smooth anvil roller 112 (or portionsthereof) may be ambient temperature or may be in the range of about 100°C. to about 300° C., about 100° C. to about 250° C., about 100° C. toabout 200° C., or about 100° C. to about 150° C., specifically recitingall 0.5° C. increments within the specified ranges and all ranges formedtherein or thereby. The pressure between the calendar roller 110 and thesmooth anvil roller 112 may be in the range of about 2,000 pli (poundsper linear inch) to about 10,000 pli, about 3,000 pli to about 8,000pli, or about 4,500 to about 6,500 pli, specifically reciting all 0.1pli increments within the specified ranges and all ranges formed thereinor thereby. As will be discussed in further detail below, after theprecursor material 102 passes through the weakening roller arrangement108, the precursor material 102 may be stretched in the CD, or generallyin the CD, by a cross directional tensioning force to at leastpartially, or fully, rupture the plurality of weakened, melt stabilizedlocations 202, thereby creating a plurality of at least partially formedapertures in the precursor material 102 coincident with the plurality ofweakened, melt stabilized locations 202.

The patterned calendar roller 110 is configured to have a cylindricalsurface 114, and a plurality of protuberances or pattern elements 116which extend outwardly from the cylindrical surface 114. The patternelements 116 are illustrated as a simplified example of a patternedcalendar roller 110, but more detailed patterned calendar rollers thatcan be used to produce patterned apertured webs of the presentdisclosure will be illustrated in subsequent figures. The protuberances116 may be disposed in a predetermined pattern with each of theprotuberances 116 being configured and disposed to precipitate aweakened, melt-stabilized location in the precursor material 102 toaffect a predetermined pattern of weakened, melt-stabilized locations202 in the precursor material 102. The protuberances 116 may have aone-to-one correspondence to the pattern of melt stabilized locations inthe precursor material 102. As shown in FIG. 17, the patterned calendarroller 110 may have a repeating pattern of the protuberances 116 whichextend about the entire circumference of surface 114. Alternatively, theprotuberances 116 may extend around a portion, or portions of thecircumference of the surface 114. Also, a single patterned calendarroller may have a plurality of patterns in various zones (i.e., firstzone, first pattern, second zone, second pattern). The protuberances 116may have a cross-directional width in the range of about 0.1 mm to about10 mm, about 0.1 mm to about 5 mm, about 0.1 mm to about 3 mm, about0.15 mm to about 2 mm, about 0.15 mm to about 1.5 mm, about 0.1 mm toabout 1 mm, about 0.1 mm to about 0.5 mm, or about 0.2 to about 0.5 mm,specifically reciting all 0.05 mm increments within the specified rangesand all ranges formed therein or thereby. The protuberances 116 may havean aspect ratio in the range of about 10:1, about 9:1, about 8:1, about7:1, about 6:1, about 5:1, about 4:1, about 3:1, about 2:1, about 1.5:1,or about 1.1:1, for example. Other aspect ratios of the protuberances116 are also within the scope of the present disclosure. Theprotuberances 116, in some forms, may be angled, relative to the machinedirection on either side, in the range of about 60 degrees to about 1degree, about 50 degrees to about 2 degrees, about 45 degrees to about 2degrees, about 45 degrees to about 5 degrees, about 40 degrees to about5 degrees, or about 35 degrees to about 5 degrees, specifically recitingall 0.1 degree increments within the specified ranges and all rangesformed therein or thereby. Spacing between adjacent protuberances 116 inany direction may be greater than about 0.5 mm, greater than about 0.6mm, greater than about 0.7 mm, greater than about 0.8 mm, greater thanabout 0.9 mm, greater than about 1 mm, greater than about 1.1 mm,greater than about 1.2 mm, greater than about 1.3 mm, greater than about1.4 mm, greater than about 1.5 mm, greater than about 2 mm, greater thanabout 3 mm, or may be in the range of about 0.7 mm to about 20 mm, orabout 0.8 to about 15 mm, specifically reciting all 0.1 mm incrementswithin the specified ranges and all ranges formed therein or thereby.

A photograph of an example roller that may be used as patterned calendarroller 110 in the process 100 of FIG. 16 to produce the patternedapertured webs of the present disclosure is illustrated in FIG. 18. Thepattern of protuberances 116 on the roller in FIG. 18 would be formed inthe precursor web 102, much like the melt-stabilized locations 202 ofFIG. 17.

The protuberances 116 may extend radially outwardly from surface 114 andhave distal end surfaces 117. The anvil roller 112 may be a smoothsurfaced, circular cylinder of steel, rubber or other material. Theanvil roller 112 and the patterned calendar roller 110 may be switchedin position (i.e., anvil on top) and achieve the same result.

From the weakening roller arrangement 108, the material 102 passesthrough a nip 130 formed by an incremental stretching system 132employing opposed pressure applicators having three-dimensional surfaceswhich at least to a degree may be complementary to one another.

Additional example patterns for protuberances 116 of roller 110 of FIG.17 are illustrated in FIGS. 19-23. The machine direction “MD” of thepatterns is indicated. The pattern of FIG. 22 was used to produce thepatterned apertured web of FIG. 3.

Referring now to FIG. 24, there is shown a fragmentary enlarged view ofthe incremental stretching system 132 comprising two incrementalstretching rollers 134 and 136. The incremental stretching roller 134may comprise a plurality of teeth 160 and corresponding grooves 161which may about the entire circumference of roller 134. The incrementalstretching roller 136 may comprise a plurality of teeth 162 and aplurality of corresponding grooves 163. The teeth 160 on the roller 134may intermesh with or engage the grooves 163 on the roller 136 while theteeth 162 on the roller 136 may intermesh with or engage the grooves 161on the roller 134. The spacing and/or pitch of the teeth 162 and/or thegrooves 163 may match the pitch and/or spacing of the plurality ofweakened, melt stabilized locations 202 in the precursor material 102 ormay be smaller or larger. As the precursor material 102 having weakened,melt-stabilized locations 202 passes through the incremental stretchingsystem 132 the precursor material 102 is subjected to tensioning in theCD causing the material 102 to be extended (or activated) in the CD, orgenerally in the CD. Additionally the material 102 may be tensioned inthe MD, or generally in the MD. The CD tensioning force placed on thematerial 102 is adjusted such that it causes the weakened,melt-stabilized locations 202 to at least partially, or fully, rupturethereby creating a plurality of partially formed, or formed apertures204 coincident with the weakened melt-stabilized locations 202 in thematerial 102. However, the bonds of the material 102 (in thenon-overbonded areas) are strong enough such that they do not ruptureduring tensioning, thereby maintaining the material 102 in a coherentcondition even as the weakened, melt-stabilized locations rupture.However, it may be desirable to have some of the bonds rupture duringtensioning.

Referring to FIG. 25, a more detailed view of the teeth 160 and 162 andthe grooves 161 and 163 on the rollers 134 and 136 is illustrated. Theterm “pitch” refers to the distance between the apexes of adjacentteeth. The pitch may be between about 0.02 inches to about 0.30 inches(about 0.51 mm to about 7.62 mm) or may be between about 0.05 inches andabout 0.15 inches (about 1.27 mm to about 3.81 mm), specificallyreciting all 0.001 inch increments within the above-specified ranges andall ranges formed therein or thereby. The height (or depth) of the teethis measured from the base of the tooth to the apex of the tooth, and mayor may not be equal for all teeth. The height of the teeth may bebetween about 0.010 inches (about 0.254 mm) and about 0.90 inches (about22.9 mm) or may be between about 0.025 inches (about 0.635 mm) and about0.50 inches (about 12.7 mm), specifically reciting all 0.01 inchincrements within the above-specified ranges and all ranges formedtherein or thereby. The teeth 160 in one roll may be offset by aboutone-half of the pitch from the teeth 162 in the other roll, such thatthe teeth of one roll (e.g., teeth 160) mesh in the valley (e.g., groove163) between teeth in the mating roll. The offset permits intermeshingof the two rolls when the rolls are “engaged” or in an intermeshing,operative position relative to one another. The teeth of the respectiverolls may only be partially intermeshing in some instances. The degreeto which the teeth on the opposing rolls intermesh is referred to hereinas the “depth of engagement” or “DOE” of the teeth. The DOE may beconstant or not constant. As shown in FIG. 25, the DOE, indicated as“E”, is the distance between a position designated by plane P1 where theapexes of the teeth on the respective rolls are in the same plane (0%engagement) to a position designated by plane P2 where the apexes of theteeth of one roll extend inward beyond the plane P1 toward the groove onthe opposing roll. The optimum or effective DOE for particular laminatewebs may be dependent upon the height and the pitch of the teeth and/orthe structure of the material. Some example DOEs may in the range ofabout 0.01 inches to about 0.5 inches, about 0.03 inches to about 0.2inches, about 0.04 inches to about 0.08 inches, about 0.05 inches, orabout 0.06 inches, specifically reciting all 0.001 inch incrementswithin the above-specified ranges and all ranges formed therein orthereby.

As the material 102 having the weakened, melt-stabilized locations 202passes through the incremental web stretching apparatus 132, thematerial 102 is subjected to tensioning in the cross machine direction,or substantially in the cross machine direction, thereby causing thenonwoven web 102 to be extended in the cross machine direction. Thetensioning force placed on the material 102 may be adjusted by varyingthe pitch, DOE, or teeth size, such that the incremental stretching issufficient to cause the weakened, melt-stabilized locations 202 to atleast partially, or fully rupture, thereby creating, or at leastpartially creating, a plurality of apertures 204 coincident with theweakened, melt-stabilized locations 202 in the material 102.

After the material 102 passes through the incremental web stretchingapparatus 132, the web 102 may be advanced to and at least partiallyaround a cross machine directional tensioning apparatus 132′ (see e.g.,FIGS. 16 and 26). The cross machine directional tensioning apparatus132′ may be offset from the main processing line by running the webpartially around two idlers 133 and 135 or stationary bars, for example.In other instances, the cross machine tensioning apparatus 132′ may bepositioned in line with the main processing line. The cross machinedirectional tensioning apparatus 132′ may comprise a roll that comprisesat least one outer longitudinal portion that expands along alongitudinal axis, A, of the roll, relative to a middle portion of theroll, to stretch and/or expand the material 102 in the cross machinedirection. Instead of or in addition to expanding along the longitudinalaxis, A, of the roll, the outer longitudinal portion may be angledrelative to the longitudinal axis, A, of the roll in a direction awayfrom the material 102 being advanced over the roll to stretch thematerial 102 in the cross machine direction or generally in the crossmachine direction. In an instance, the roll may comprise two outerlongitudinal portions that each may expand in opposite directionsgenerally along the longitudinal axis, A, of the roll. The two outerportions may both be angled downwards in a direction away from thematerial 102 being advanced over the roll. This movement or positioningof the outer longitudinal portions of the roll allows for generallycross machine directional tensioning of the material 102, which causesthe plurality of weakened locations 202 to rupture and/or be furtherdefined or formed into apertures 204.

The outer longitudinal portions of the roll may comprise vacuum, a lowtack adhesive, a high coefficient of friction material or surface, suchas rubber, and/or other mechanisms and/or materials to hold the material102 to the outer lateral portions of the roll during movement of theouter longitudinal portion or portions relative to the middle portion ofthe roll. The vacuum, low tack adhesive, high coefficient of frictionmaterial or surface, and/or other mechanisms and/or materials mayprevent, or at least inhibit, the held portions of the material 102 fromslipping relative to the longitudinal axis, A, of the roll duringstretching of the outer lateral portions of the material in the crossmachine direction or generally in the cross machine direction.

FIG. 26 is a top perspective view of the example cross machinedirectional tensioning apparatus 132′. The cross machine directionaltensioning apparatus 132′ may comprise a roll comprising a middleportion 2000 and two outer longitudinal portions 2020 situated on eitherend of the middle portion 2000. The roll may rotate about itslongitudinal axis, A, on a drive shaft 2040. The roll may rotaterelative to the drive shaft 2040 or in unison with the drive shaft 2040,as will be recognized by those of skill in the art. The material 102 maybe advanced over the entire cross machine directional width of themiddle portion 2000 and at least portions of the cross machinedirectional widths of the outer longitudinal portions 2020. The material102 may be advanced over at least about 5% up to about 80% of thecircumference of the roll so that the cross machine directionalstretching may be performed.

FIG. 27 is a schematic representation of a front view of an examplecross machine directional tensioning apparatus with outer longitudinalportions 2020 in an unexpanded or non-angled position relative to themiddle portion 2000. FIG. 28 is a schematic representation of a frontview of the cross machine directional tensioning apparatus of FIG. 27with the outer longitudinal portions 2020 in a longitudinally expandedposition relative to the middle portion 2000. FIG. 29 is a schematicrepresentation of a front view of the cross machine directionaltensioning apparatus of FIG. 27 with the outer longitudinal portions2020 in an angled and expanded position relative to the middle portion2000. In regard to FIG. 29, the outer longitudinal portions 2020 maymerely move or slide in a direction generally perpendicular to themachine direction of the material passing over the roll to apply thecross machine directional tensioning force to the material 102. FIG. 30is a schematic representation of a front view of a cross machinedirectional tensioning apparatus with the outer longitudinal portions2020 fixed in an angled position relative to the middle portion 2000 toapply the cross machine directional tensioning force to the material102. In such a form, the middle portion 2000 and each of the outerlongitudinal portions 2020 may comprise a separate roll.

Regardless of whether one or both of the outer longitudinal portions2020 is moved, slid, rotated, fixed, and/or expanded relative to themiddle portion 2000, this relative motion or positioning between theouter longitudinal portions 2020 and the middle portion 2000 stretchesthe materials 102 in a cross machine direction to further rupture orfurther define the weakened locations 2020 in the material 102 andcreate, or further form, a plurality the apertures 2040 the material102. The cross machine directional tensioning force applied by the crossmachine directional tensioning apparatus 132′ may be, for example, 10-25grams or 15 grams. In an instance, the cross machine directionaltensioning apparatus may be similar to, or the same as, the incrementalstretching apparatus 132 to apply the cross machine directionaltensioning force. In still other instances, any suitable cross machinedirectional tensioning apparatus may be used to apply the cross machinedirectional tensioning force to the material 102.

If desired, the incremental stretching step or the cross machinedirectional stretching step described herein may be performed atelevated temperatures. For example, the material 102 and/or the rollsmay be heated. Utilizing heat in the stretching step may serve to softenthe material, and may aid in extending the fibers without breaking.

Referring again to FIG. 16, the material 102 may be taken up on wind-uproll 180 and stored. Alternatively, the material 102 may be fed directlyto a production line where it is used to form a portion of an absorbentarticle or other consumer product.

It is important to note that the overbonding step illustrated in FIGS.16 and 17 could be performed by the material supplier and then thematerial may be shipped to a consumer product manufacturer to performstep 132. In fact, the overbonding step may be used in the nonwovenproduction process to form overbonds, which may be in addition to, or inlieu of, primary bonds formed in the nonwoven production process.Alternatively, the material supplier may fully perform the stepsillustrated in FIG. 16 and then the material may be shipped to theconsumer product manufacturer. The consumer product manufacturer mayalso perform all of the steps in FIG. 16 after obtaining a nonwovenmaterial from a nonwoven material manufacturer.

One of ordinary skill in the art will recognize that it may beadvantageous to submit the material 102 to multiple incrementalstretching processes depending on various desired characteristics of thefinished product. Both the first and any additional incrementalstretching may either be done on-line or off-line. Furthermore, one ofordinary skill will recognize that the incremental stretching may bedone either over the entire area of the material or only in certainregions of the material depending on the final desired characteristics.

Returning now to FIGS. 11-15, there is shown photographs of examplepatterned apertured webs after having been subjected to the tensioningforce applied by the incremental stretching system 132 and the crossmachine directional tensioning apparatus 132′. As can be seen in thephotographs of FIGS. 11-15, the patterned apertured webs now include aplurality of apertures 204 which are coincident with the weakened,melt-stabilized locations made by the roller 110 (with variouspatterns). A portion of the circumferential edges of an aperture 204 mayinclude remnants 205 of the melt-stabilized locations. It is believedthat the remnants 205 help to resist further tearing of the materialparticularly when the material is used as a portion of an absorbentarticle or another consumer product.

Percent of CD Stretch

The extent to which the material 102 is stretched in the CD may have acorrelation to the size, shape, and area of the apertures. In general,the apertures may have a larger area and be more open the more thematerial 102 is stretched in the CD direction by the cross machinedirectional tensioning apparatus 132′. As such, a manufacturer canfurther vary an aperture pattern based on the amount of CD tensioningapplied to a material even when the melt-stabilized pattern in thematerial is the same. As an example, FIG. 31 illustrates an overbondpattern in a material 102 prior to the incrementally stretching step 132and the cross machine directional tension step 132′. The plurality ofmelt-stabilized locations are indicated as 202. The material is then runthrough the incrementally stretching step 132 and the cross machinedirectional tensioning apparatus 132′. The cross machine directionaltensioning apparatus 132′ may be set to extend the material 102 to over100% of its CD width “W” after exiting the incremental stretchingapparatus 132, such as 125%, 135%, 145%, 155% of W. In other instances,the material 102 may be stretched in the cross machine direction in therange of about 110% to about 180% of W, about 120% to about 170% of W,specifically reciting all 0.5% increments within the specified rangesand all ranged formed therein or thereby. FIG. 32 illustrates an exampleof the material 102 with the overbond pattern of FIG. 31 and stretchedto 125% of W. FIG. 33 illustrates an example of the material 102 withthe overbond pattern of FIG. 31 and stretched to 135% of W. FIG. 34illustrates an example of the material 102 with the overbond pattern ofFIG. 31 and stretched to 145% of W. FIG. 35 illustrates an example ofthe material 102 with the overbond pattern of FIG. 31 and stretched to155% of W. As illustrated, the amount of CD stretch can be a significantfactor on the patterned apertured web produced.

Absorbent Article

As described herein, the patterned apertured webs of the presentdisclosure may be used as one or more components of an absorbentarticle. An example absorbent article is set forth below. FIG. 36 is aplan view of an example absorbent article that is a diaper 520 in itsflat-out, uncontracted state (i.e., with elastic induced contractionpulled out) with portions of the structure being cut-away to moreclearly show the construction of the diaper 520 and with the portion ofthe diaper 520 which faces the wearer, the inner surface 540, facing theviewer. The diaper 520 may comprise a chassis 522 comprising a liquidpervious topsheet 524, a liquid impervious backsheet 26 joined to thetopsheet, and an absorbent core 528 positioned at least partiallybetween the topsheet 24 and the backsheet 26. The diaper 520 maycomprise elasticized side panels 530, elasticized leg cuffs 532,elasticized waistbands 534, and a fastening system 536 that may comprisea pair of securement members 537 and a landing member or landing zone ona garment-facing surface or outer surface 542. The diaper 520 may alsocomprise an outer cover 533 that may comprise one or more of thepatterned adhesive webs of the present disclosure. The outer cover 533may comprise nonwoven materials and/or films.

The diaper 520 is shown to have an inner surface 540 (facing the viewerin FIG. 36), an outer surface 542 opposed to the inner surface 540, arear waist region 544, a front waist region 546 opposed to the rearwaist region 544, a crotch region 548 positioned between the rear waistregion 544 and the front waist region 546, and a periphery which isdefined by the outer perimeter or edges of the diaper 520 in which thelongitudinal edges are designated 550 and the end edges are designated552. The inner surface 540 of the diaper 520 comprises that portion ofthe diaper 520 which is positioned adjacent to the wearer's body duringuse (i.e., the inner surface 540 generally is formed by at least aportion of the topsheet 524 and other components joined to the topsheet524). The outer surface 542 comprises that portion of the diaper 520which is positioned away from the wearer's body (i.e., the outer surface542 is generally formed by at least a portion of the backsheet 526 andother components joined to the backsheet 526). The rear waist region 544and the front waist region 546 extend from the end edges 552 of theperiphery to the crotch region 548.

The diaper 520 also has two centerlines, a longitudinal centerline 590and a transverse centerline 592. The term “longitudinal”, as usedherein, refers to a line, axis, or direction in the plane of the diaper520 that is generally aligned with (e.g., approximately parallel with) avertical plane which bisects a standing wearer into left and righthalves when the diaper 520 is worn. The terms “transverse” and“lateral”, as used herein, are interchangeable and refer to a line, axisor direction which lies within the plane of the diaper that is generallyperpendicular to the longitudinal direction (which divides the wearerinto front and back body halves).

The chassis 522 of the diaper 520 is shown in FIG. 36 as comprising themain body of the diaper 520. The containment assembly 522 may compriseat least the topsheet 524, the backsheet 526, and the absorbent core528. When the absorbent article 520 comprises a separate holder and aliner, the chassis 522 may comprise the holder and the liner (i.e., thechassis 522 comprises one or more layers of material to define theholder while the liner comprises an absorbent composite such as atopsheet, a backsheet, and an absorbent core.) For unitary absorbentarticles (or one piece), the chassis 522 comprises the main structure ofthe diaper with other features added to form the composite diaperstructure. Thus, the chassis 522 for the diaper 520 generally comprisesthe topsheet 524, the backsheet 526, and the absorbent core 528.

FIG. 36 shows a form of the chassis 522 in which the topsheet 524 andthe backsheet 526 have length and width dimensions generally larger thanthose of the absorbent core 528. The topsheet 524 and the backsheet 526extend beyond the edges of the absorbent core 528 to thereby form theperiphery of the diaper 520. While the topsheet 524, the backsheet 526,and the absorbent core 528 may be assembled in a variety of well knownconfigurations know to those of skill in the art.

The absorbent core 528 may be any absorbent member which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. As shown in FIG. 36, the absorbent core 528 has agarment-facing side, a body-facing side, a pair of side edges, and apair of waist edges. The absorbent core 528 may be manufactured in awide variety of sizes and shapes (e.g., rectangular, hourglass,“T”-shaped, asymmetric, etc.) and from a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp which is generallyreferred to as airfelt. The absorbent core may comprise superabsorbentpolymers (SAP) and less than 15%, less than 10%, less than 5%, less than3%, or less than 1% of airfelt, or be completely free of airfelt.Examples of other suitable absorbent materials comprise creped cellulosewadding, meltblown polymers including coform, chemically stiffened,modified or cross-linked cellulosic fibers, tissue including tissuewraps and tissue laminates, absorbent foams, absorbent sponges,superabsorbent polymers, absorbent gelling materials, or any equivalentmaterial or combinations of materials. The absorbent core may alsocomprise SAP and air felt in any suitable ranges.

The configuration and construction of the absorbent core 528 may vary(e.g., the absorbent core may have varying caliper zones, a hydrophilicgradient, a superabsorbent gradient, or lower average density and loweraverage basis weight acquisition zones; or may comprise one or morelayers or structures). Further, the size and absorbent capacity of theabsorbent core 528 may also be varied to accommodate wearers rangingfrom infants through adults. However, the total absorbent capacity ofthe absorbent core 528 should be compatible with the design loading andthe intended use of the diaper 520.

Referring to FIGS. 37-39, the absorbent core 528 of the absorbentarticles may comprise one or more channels 626, 626′, 627, 627′ (627 and627′ are shown in dash in FIG. 36), such as two, three, four, five, orsix channels. The absorbent core 528 may comprise a front side 280, arear side 282, and two longitudinal sides 284, 286 joining the frontside 280 and the rear side 282. The absorbent core 528 may comprise oneor more absorbent materials. The absorbent material 628 of the absorbentcore 528 may be distributed in higher amounts towards the front side 280than towards the rear side 282 as more absorbency may be required at thefront of the absorbent core 528 in particular absorbent articles. Thefront side 280 may be positioned generally in the front waist region ofan absorbent article and the rear side 282 may be positioned generallyin the rear waist region of an absorbent article.

A core wrap (i.e., the layers enclosing the absorbent material of theabsorbent core 528) may be formed by two nonwoven materials, substrates,laminates, films, or other materials 616, 616′. The core wrap may be atleast partially sealed along the front side 280, the rear side 282,and/or the two longitudinal sides 284, 286 of the absorbent core 528 sothat substantially no absorbent material is able to exit the core wrap.In a form, the core wrap may only comprise a single material, substrate,laminate, or other material wrapped at least partially around itself.The first material, substrate, or nonwoven 616 may at least partiallysurround a portion of the second material, substrate, or nonwoven 116′to form the core wrap, as illustrated as an example in FIG. 37. Thefirst material 616 may surround a portion of the second material 616′proximate to the first and second side edges 284 and 286 and/or thefront side 280 and the rear side 282. Patterned apertured webs of thepresent disclosure may have forms where the patterned apertures in, forexample a topsheet, a wearer-facing laminate, an outer cover, and/or agarment-facing laminate may only have patterned apertures overlapping atleast some of the core channels (e.g., channels 626 and 626′ of FIG.37). In other instances, the patterned apertures in the topsheet, thewearer-facing laminate, the outer cover, and/or the garment-facinglaminate may coordinate with or compliment the core channels in such away as the core channels are highlighted to a caregiver or wearer. Thisconcept may also apply to sanitary napkins having core channels.

The absorbent core 528 of the present disclosure may comprise one ormore adhesives, for example, to help immobilize the SAP or otherabsorbent materials within the core wrap and/or to ensure integrity ofthe core wrap, in particular when the core wrap is made of two or moresubstrates. The core wrap may extend to a larger area than required forcontaining the absorbent material(s) within.

Absorbent cores comprising relatively high amounts of SAP with variouscore designs are disclosed in U.S. Pat. No. 5,599,335 to Goldman et al.,EP 1,447,066 to Busam et al., WO 95/11652 to Tanzer et al., U.S. Pat.Publ. No. 2008/0312622A1 to Hundorf et al., and WO 2012/052172 to VanMalderen.

The absorbent material may comprise one or more continuous layerspresent within the core wrap with channels having no, or little (e.g.,0.1%-10%) absorbent material positioned therein. In other forms, theabsorbent material may be formed as individual pockets or stripes withinthe core wrap. In the first case, the absorbent material may be, forexample, obtained by the application of the continuous layer(s) ofabsorbent material, with the exception of the absorbent material free,or substantially free, channels. The continuous layer(s) of absorbentmaterial, in particular of SAP, may also be obtained by combining twoabsorbent layers having discontinuous absorbent material applicationpatterns, wherein the resulting layer is substantially continuouslydistributed across the absorbent particulate polymer material area, asdisclosed in U.S. Pat. Appl. Pub. No. 2008/0312622A1 to Hundorf et al.,for example. The absorbent core 528 may comprise a first absorbent layerand at least a second absorbent layer. The first absorbent layer maycomprise the first material 616 and a first layer 661 of absorbentmaterial, which may be 100% or less of SAP, such as 85% to 100% SAP, 90%to 100% SAP, or even 95% to 100% SAP, specifically including all 0.5%increments within the specified ranges and all ranges formed therein orthereby. The second absorbent layer may comprise the second material616′ and a second layer 662 of absorbent material, which may also be100% or less of SAP (including the ranges specified above). Theabsorbent core 528 may also comprise a fibrous thermoplastic adhesivematerial 651 at least partially bonding each layer of the absorbentmaterial 661, 662 to its respective material 616, 616′. This isillustrated in FIGS. 38 and 39, as an example, where the first andsecond SAP layers have been applied as transversal stripes or “landareas” having the same width as the desired absorbent materialdeposition area on their respective substrate before being combined. Thestripes may comprise different amount of absorbent material (SAP) toprovide a profiled basis weight along the longitudinal axis 580′ of thecore 528.

The fibrous thermoplastic adhesive material 651 may be at leastpartially in contact with the absorbent material 661, 662 in the landareas and at least partially in contact with the materials 616 and 616′in the channels 626, 626′. This imparts an essentially three-dimensionalstructure to the fibrous layer of thermoplastic adhesive material 651,which in itself is essentially a two-dimensional structure of relativelysmall thickness, as compared to the dimension in length and widthdirections. Thereby, the fibrous thermoplastic adhesive material 651 mayprovide cavities to cover the absorbent material in the land areas, andthereby immobilizes this absorbent material, which may be 100% or lessof SAP (including the ranges specified above).

The channels 626, 626′ may be continuous or discontinuous and may have alength of L′ and a width, W_(c), for example, or any other suitablelength or width. The channels 626, 626′, 627, and 627′ may have alateral vector component and a longitudinal vector component or mayextend entirely longitudinally or entirely laterally. The channels mayeach have one or more arcuate portions. One or more channels may extendacross the lateral axis or the longitudinal axis 580′ of the absorbentcore 528, or both.

Referring to FIG. 38, it can be seen that the channels 626 and 626′ donot comprise absorbent material. In other instances, the channels 626and 626′ may comprise a relatively small amount (compared to the amountof the absorbent material within the remainder of the absorbent core528) of absorbent material. The relatively small amount of absorbentmaterial within the channels may be in the range of 0.1% to 20%,specifically reciting all 0.1% increments within the specified rangesand all ranges formed therein.

Referring again to FIG. 37, the absorbent core 528 may comprise one ormore pockets 650 (shown in dash). The one or more pockets 650 may beprovided in addition to the one or more channels or instead of the oneor more channels. The pockets 650 may be areas in the absorbent core 528that are free of, or substantially free of absorbent material, such asSAP (including the ranges specified above). The pockets 650 may overlapthe longitudinal axis 580′ and may be positioned proximate to the frontside 280, the rear side 282, or may be positioned at a locationintermediate the front side 280 and the rear side 282, such aslongitudinally centrally, or generally longitudinally centrally betweenthe front side 280 and the rear side 282.

Other forms and more details regarding channels and pockets that arefree of, or substantially free of absorbent materials, such as SAP,within absorbent cores are discussed in greater detail in U.S. PatentApplication Publication Nos. 2014/0163500, 2014/0163506, and2014/0163511, all published on Jun. 12, 2014.

The diaper 520 may have an asymmetric, modified T-shaped absorbent core528 having ears in the front waist region 546 but a generallyrectangular shape in the rear waist region 544. Example absorbentstructures for use as the absorbent core 528 of the present disclosurethat have achieved wide acceptance described in U.S. Pat. No. 4,610,678,entitled “High-Density Absorbent Structures” issued to Weisman et al.,on Sep. 9, 1986; U.S. Pat. No. 4,673,402, entitled “Absorbent ArticlesWith Dual-Layered Cores”, issued to Weisman et al., on Jun. 16, 1987;U.S. Pat. No. 4,888,231, entitled “Absorbent Core Having A DustingLayer”, issued to Angstadt on Dec. 19, 1989; and U.S. Pat. No.4,834,735, entitled “High Density Absorbent Members Having Lower Densityand Lower Basis Weight Acquisition Zones”, issued to Alemany et al., onMay 30, 1989. The absorbent core may further comprise the dual coresystem containing an acquisition/distribution core of chemicallystiffened fibers positioned over an absorbent storage core as detailedin U.S. Pat. No. 5,234,423, entitled “Absorbent Article With ElasticWaist Feature and Enhanced Absorbency” issued to Alemany et al., on Aug.10, 1993; and in U.S. Pat. No. 5,147,345 entitled “High EfficiencyAbsorbent Articles For Incontinence Management”, issued to Young et al.on Sep. 15, 1992.

The backsheet 526 is positioned adjacent the garment-facing surface ofthe absorbent core 528 and may be joined thereto by attachment methods(not shown) such as those well known in the art. For example, thebacksheet 526 may be secured to the absorbent core 528 by a uniformcontinuous layer of adhesive, a patterned layer of adhesive, or an arrayof separate lines, spirals, or spots of adhesive. Alternatively, theattachment methods may comprise using heat bonds, pressure bonds,ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment methods or combinations of these attachment methods as areknown in the art. Forms of the present disclosure are also contemplatedwherein the absorbent core is not joined to the backsheet 526, thetopsheet 524, or both in order to provide greater extensibility in thefront waist region 546 and the rear waist region 544.

The backsheet 526 may be impervious, or substantially impervious, toliquids (e.g., urine) and may be manufactured from a thin plastic film,although other flexible liquid impervious materials may also be used. Asused herein, the term “flexible” refers to materials which are compliantand will readily conform to the general shape and contours of the humanbody. The backsheet 526 may prevent, or at least inhibit, the exudatesabsorbed and contained in the absorbent core 528 from wetting articleswhich contact the diaper 520 such as bed sheets and undergarments,however, the backsheet 526 may permit vapors to escape from theabsorbent core 528 (i.e., is breathable). Thus, the backsheet 526 maycomprise a polymeric film such as thermoplastic films of polyethylene orpolypropylene. A suitable material for the backsheet 526 is athermoplastic film having a thickness of from about 0.012 mm (0.5 mil)to about 0.051 mm (2.0 mils), for example.

The topsheet 524 is positioned adjacent the body-facing surface of theabsorbent core 528 and may be joined thereto and to the backsheet 526 byattachment methods (not shown) such as those well known in the art.Suitable attachment methods are described with respect to joining thebacksheet 526 to the absorbent core 528. The topsheet 524 and thebacksheet 526 may be joined directly to each other in the diaperperiphery and may be indirectly joined together by directly joining themto the absorbent core 528 by the attachment methods (not shown).

The topsheet 524 may be compliant, soft feeling, and non-irritating tothe wearer's skin. Further, the topsheet 524 may be liquid perviouspermitting liquids (e.g., urine) to readily penetrate through itsthickness. A suitable topsheet 524 may comprise one or more of thepatterned apertured webs of the present disclosure forming one or morelayers. As described herein, the patterned apertured webs of the presentdisclosure may form any other suitable components, or portions thereof,of an absorbent article or the example diaper 520, such as an outercover; an outer cover and a backsheet; a carrier layer (as referencedabove); an ear panel; an acquisition material; a distribution material;an acquisition material and a topsheet; a distribution material and atopsheet; a first acquisition material; a second acquisition material; afirst acquisition or distribution material and a second acquisition ordistribution material; a topsheet, a first acquisition or distributionmaterial, and a second acquisition or distribution material; a topsheet,a patch joined to or positioned on a topsheet; and a topsheet and asecondary topsheet, for example. Apertures may be formed through any orall of these materials, for example. In an example, an apertured orpatterned apertured topsheet may be embossed or otherwise joined to anacquisition material, to an acquisition material and a distributionmaterial, or to an acquisition material, a distribution material and acarrier layer, for example.

In an instance of a patterned apertured web, a first layer may comprisea topsheet and a second layer may comprise an acquisition material orlayer. The acquisition material or layer may be a discrete patch that isnot as long and/or wide as the topsheet or that may be the same size asthe topsheet. The first layer and/or the second layer may have patternedapertures having any of the features described herein. Either of thelayers may be pre-strained prior to being joined to the other layer, asdescribed herein, thereby creating three-dimensional features in thetopsheet/acquisition material laminate. By providing a patternedapertured web comprising a topsheet as a first layer and comprising anacquisition material as a second layer, improved fluid acquisition maybe achieved as well as improved depth perception of the absorbentarticle owing to the relatively high basis weight of the acquisitionmaterial. In a feminine care context, the acquisition material may be asecondary topsheet.

Sanitary Napkin

Referring to FIG. 40, the absorbent article may be a sanitary napkin310. A topsheet, a secondary topsheet, wings, or another portion of thesanitary napkin may comprise one or more of the patterned apertured websof the present disclosure. The sanitary napkin 310 may comprise a liquidpermeable topsheet 314, a liquid impermeable, or substantially liquidimpermeable, backsheet 316, and an absorbent core 318 positionedintermediate the topsheet 314 and the backsheet 316. The absorbent core318 may have any or all of the features described herein with respect tothe absorbent cores 28 and, in some forms, may have a secondary topsheetinstead of the acquisition layer(s) disclosed above. The sanitary napkin310 may comprise wings 320 extending outwardly with respect to alongitudinal axis 380 of the sanitary napkin 310. The sanitary napkin310 may also comprise a lateral axis 390. The wings 320 may be joined tothe topsheet 314, the backsheet 316, and/or the absorbent core 318. Thesanitary napkin 310 may also comprise a front edge 322, a rear edge 324longitudinally opposing the front edge 322, a first side edge 326, and asecond side edge 328 longitudinally opposing the first side edge 326.The longitudinal axis 380 may extend from a midpoint of the front edge322 to a midpoint of the rear edge 324. The lateral axis 390 may extendfrom a midpoint of the first side edge 328 to a midpoint of the secondside edge 328. The sanitary napkin 310 may also be provided withadditional features commonly found in sanitary napkins as is known inthe art.

Patterned Adhesive

Any of the patterned apertured webs and/or absorbent articles of thepresent disclosure, or portions thereof, may comprise one or morepatterned adhesives applied thereto or printed thereon. The patternedadhesives may be present on the patterned apertured webs or under thepatterned apertured webs such that at least a portion of the patternedadhesives may be viewable through the patterned apertured webs, eitherthough apertures or non-apertured areas. Patterned adhesives areadhesives that are applied to one or more layers of the patternedapertured webs, or between layers of the same, in particular patterns toprovide the absorbent articles, or portions thereof, with certainpatterns, visible patterns, and/or certain textures.

FIGS. 41 and 42 illustrate example patterns of adhesives, or pigmentedadhesives, that can be used with the patterned apertured webs of thepresent disclosure. For example, these adhesive patterns may be usedwith the example patterned apertured web pattern of FIG. 15. Thesepatterned adhesives can also be used with non-apertured layers havingoverbonds or embossments. The patterned adhesives may be printed on oneor more apertured or non-apertured layers of the patterned aperturedwebs or patterned webs having embossments or overbonds. Other adhesivepatterns having any suitable configuration are also within the scope ofthe present disclosure. The patterned adhesives may be printed on orotherwise applied to any suitable layer of the patterned apertured websor applied above or beneath them. Methods for applying patternedadhesives to layers or substrates by adhesive printing are disclosed,for example, in U.S. Pat. No. 8,186,296, to Brown et al., issued on May29, 2012, and in U.S. Pat. Appl. Publ. No. 2014/0148774, published onMay 29, 2014, to Brown et al. Other methods of applying patternedadhesives to substrates known to those of skill in the art are alsowithin the scope of the present disclosure.

A patterned adhesive may have the same color or a different color as atleast one layer of a patterned apertured web. In some instances, thepatterned adhesive may have the same or a different color as both or alllayers of a patterned apertured web. In some instances, aperturepatterns in at least one layer of a patterned apertured web maycoordinate with a patterned of a patterned adhesive to visually create athree-dimensional appearance. The apertured patterns may be the same ordifferent than patterns of the patterned adhesive.

In an instance, a patterned apertured web may comprise a first layercomprising a plurality of apertures and a plurality of land areas and asecond layer comprising a plurality of apertures and a plurality of landareas. A patterned pigmented substance, such as ink or a patternedadhesive, may be positioned at least partially intermediate the firstlayer and the second layer. The patterned pigmented substance may bepositioned on land areas of the first layer and/or the second layer. Theplurality of apertures of the first layer may be at least partiallyaligned with the plurality of apertures of the second layer (see e.g.,FIG. 8). The patterned pigmented or colored substance (e.g., 29 of FIG.8) may be at least partially viewable through the apertures in one ofthe first or second layers.

Patterns

The apertures in at least one layer of a patterned apertured web may begrouped in spaced arrays of apertures (see e.g., FIGS. 1-4 and 43). FIG.43 shows example arrays of apertures, labeled as “A”. An aperture arraymay include two or more, or three or more apertures having much closerspacing between the apertures than the distance between the aperturearrays. The distance between the array and other apertures may be atleast about 1.5, at least about 2 times, or at least about 3 times themaximum distance between apertures in the array. The aperture arrays mayform a regular or recognizable shape, such as a heart shape, polygon,ellipse, arrow, chevron, and/or other shapes known in the pattern art.The apertures arrays may differ in one portion of the patternedapertured web compared to another portion of the patterned aperturedweb. In an absorbent article context, the aperture arrays may differ inone region of the absorbent article compared to another region of theabsorbent article. The aperture arrays may have perimeters that areconcave, convex, or may include concavities and convexities. Theaperture arrays may be organized into “macro-arrays” having a higherorder structure. For example, referring to FIGS. 43 and 44, a patternedapertured web 1000 is illustrated with aperture arrays 1002 that may beseparated by a continuous, inter-connected land area pattern 1004. Insuch an instance, the land area pattern 1004 may function as a fluiddistribution pathway and the aperture arrays 1002 may function as fluid“drains” thereby promoting fluid access to the underlying absorbentmaterial or absorbent core. The shape of the aperture arrays may enhancethe ability of the arrays to manage fluid, such as bodily exudates(i.e., urine, runny BM, menses). For example, aperture arrays includinga concavity facing a fluid insult location in an absorbent article mayfunction as fluid collection “traps” as the fluid may travel along the“land area” in the concavity to a point where the concavity ends. Atthis location, the fluid may enter the apertures in the direction of thefluid path or those on either side of the concavity if the fluid turnsin either lateral direction. Example aperture array shapes having aconcavity include heart shapes, star shapes, some polygons, crescents,and chevrons, to name a few examples.

In an instance, referring to FIGS. 45-47, apertures, or arrays thereof,in a patterned apertured web 1000, may form one or more continuous orsemi-continuous patterns 1006, resulting in discrete “macro” land areas1008. In such an instance, the discrete macro land areas 1008 mayfunction as fluid deposition regions. Fluid moving from the discretemacro land areas 1008 in any direction may be absorbed into theapertures of the continuous or semi-continuous pattern 1006.

In an instance, referring to FIGS. 48-52, the apertures, or aperturearrays thereof, in a patterned apertured web 1000 may form linearpatterns 1110 alternating with continuous or semi-continuous land areas1112. The patterned apertured webs may include unidirectional ormulti-directional (and intersecting) aperture or aperture arraypatterns. Linear aperture or array patterns may be oriented parallel tothe longitudinal or lateral axis, or at an angle between 0 and 90degrees, specifically reciting all 0.5 degree increments within thespecified range and all ranges formed therein, from either thelongitudinal or lateral axis. Linear apertures or aperture arraypatterns may function to restrict fluid movement along the patternedapertured web to a greater degree in one direction compared to anotherdirection.

The aperture pattern in a patterned apertured web may coordinate withgraphics, indicia, printing, inks, color, and/or patterned adhesives,for example, located beneath the patterned apertured web or within thepatterned apertured web. In an instance, the patterned apertured web maybe used a topsheet, an outer cover, an ear, wings of a sanitary napkin,or other portion of an absorbent article.

The aperture pattern in a patterned apertured web may coordinate withfeatures under it, such as bond sites, material edges, channels, and/ordiscolored or colored materials. By coordinating with these features itis meant that the patterned apertured web may be used to accentuate orblock/hide these features. The aperture patterns of a patternedapertured web may also be used to indicate the correct front vs. rear,left vs. right orientation of an absorbent article or other consumerproduct.

If a patterned apertured web is used as part, or all of, an outer cover(garment-facing layer) of an absorbent article, the aperture pattern orpatterns may provide enhanced breathability in certain regions (e.g.,waist, hips) or reduced breathability in areas over an absorbent core,for example. The aperture pattern or patterns in a patterned aperturedweb used as an outer cover may also provide enhanced textures and/orsignals in certain regions of the outer cover. Such texture and/orsignals may provide intuitive instructions on how to property apply theabsorbent article, where to grip the absorbent article, and/or where/howto fasten the absorbent article, among other functions, such as toenhance graphics or aesthetics.

If a patterned apertured web is used as a portion of a leg cuff of anabsorbent article, an apertured pattern of the patterned apertured webof the leg cuff may coordinate with an aperture pattern of a patternedapertured web used as a topsheet and/or an outer cover of the sameabsorbent article to signal a holistic function.

If a patterned apertured web is used as a portion of a fastener (e.g.,taped fastener) of an absorbent article, an apertured pattern of apatterned apertured web of the fastener may indicate how to grip andfasten the fastener and indicate when it is and is not fastenedcorrectly. An apertured pattern of the patterned apertured web used as afastener, or portion thereof, may coordinate with an aperture pattern ofa patterned apertured web used as a topsheet and/or an outer cover ofthe same absorbent article to signal a holistic function.

The optimum balance of bodily exudate acquisition speed and rewet in anabsorbent article comprising a patterned apertured web as a topsheetand/or topsheet and acquisition system may be derived from a combinationof aperture diameter, shape or area, depth or thickness of the patternedapertured web, and the spacing between the various apertures or aperturearrays within the patterned apertured web.

An absorbent article comprising a patterned apertured web as a topsheetand/or a topsheet and an acquisition system may comprise a longitudinalaxis, much like the longitudinal axis of 590 of FIG. 36. Arrays ofapertures in the patterned apertured web may repeat themselves along aline that is angled about 20 degrees to about 160 degrees, specificallyreciting all 1 degree increments within the specified range and allranges formed therein, relative to the longitudinal axis. Additionally,there may be a plurality of aperture sizes, shapes, or areas along theline or the spacing between the apertures may not the same between allof the apertures along the line for purposes of channeling liquid bodilyexudates into preferred areas of the absorbent article or the absorbentcore thereof to help avoid leakage.

An aperture pattern in a patterned apertured web may form a recognizablevisual element, such as a heart or a water droplet, for example. Anaperture pattern that forms one or more water droplet shapes in apatterned apertured web used as a topsheet or an outer cover of anabsorbent article may be used to aid communication of absorbency and/orwetness. Such a feature may be combined with a wetness indicator of anabsorbent article.

Various commonly understood shapes may be created in a patternedapertured web. These shapes may be shapes that have commonly understoodproper orientations, such as hearts, for example. An example is the useof one or more hearts on an outer cover or a topsheet of a front waistregion and/or a back waist region of a diaper. The caregiver wouldunderstand to place the diaper on the wearer with the point of the heartfacing toward the wearer's feet because of the common knowledge of theorientation of hearts.

In an instance, a patterned apertured web may comprise a firstnon-apertured layer comprising a pattern having a color and a secondpatterned apertured layer comprising a pattern of apertures. The patternon the first non-apertured layer may be printed on the layer, forexample, and may form graphics or other indicia. At least 50% to 100% ofthe pattern on the first non-apertured layer may be aligned with thepattern of apertures in the second patterned apertured layer to drawattention to the apertures. The alignment, or partial alignment, of thepattern of apertures on the first layer with the pattern having a colorof the second layer may make aid in aligning the product on a wearer ifthe patterned apertured web is provided on an absorbent article.

Zones

In any context of a patterned apertured web, but especially in anabsorbent article context, the patterned apertured webs may be employedin a zonal fashion. For instance, a first zone of a topsheet or outercover of an absorbent article may have a first patterned apertured webhaving a first pattern, while a second zone of the topsheet or the outercover of the absorbent may have a second patterned apertured web havinga second, different pattern. In a topsheet context, for example, thepatterns in the different zones may be configured to receive certainbodily exudates or inhibit or encourage their flow in any desireddirection. For example, the first pattern may be better configured toreceive and/or direct the flow of urine, while the second pattern may bebetter configured to receive and/or direct the flow of runny BM. Inother instances where the patterned apertured webs are used as atopsheet of an absorbent article, a first patterned apertured web havinga first pattern may be configured to receive heavy gushes of bodilyexudates, while a second patterned apertured web having a seconddifferent pattern may be configured to restrict lateral bodily exudateflow in any desired direction. The first pattern may be situated in, forinstance, the middle of the absorbent article or in the crotch region,while the second pattern may be situated in the front and rear waistregions or outer perimeter topsheet regions of the absorbent article.

The zones in a patterned apertured web may be positioned in the machinedirection, the cross direction, or may be concentric. If a product, suchas an absorbent article, has two different zones in the machinedirection, the zones may have the same or a similar cross-directionwidth (e.g., +/−2 mm) for ease in processing. One or more of the zonesmay have curved or straight boundaries or partial boundaries.

Any suitable zones, including more than two, of different or the samepatterned apertured webs, are envisioned within the scope of the presentdisclosure. The various zones may be in the topsheet as mentioned above,but may also be present on an outer cover, a barrier leg cuff, or anyother portion of ab absorbent article or other product, for example. Insome instances, the same or a different pattern of zones of patternedapertured webs may be used on the wearer-facing surface (e.g., topsheet)and the garment-facing surface (e.g., outer cover).

In an instance, a topsheet or other portion of an absorbent article mayhave two or more zones in a patterned apertured web. A first zone of thepatterned apertured web may have a different aperture pattern than asecond zone. The first zone and the second zone may have differentfunctionalities owing to the different aperture patterns. Afunctionality of the first zone may be to provide liquid bodily exudatedistribution (fluid moving on the patterned apertured web), while thefunctionality of the second zone may be to provide liquid bodily exudateacquisition (fluid penetrating the patterned apertured web). Benefits ofsuch a zoned patterned apertured web can be better use of an absorbentcore and more efficient liquid bodily exudate distribution within theabsorbent core.

In an instance, an absorbent article may comprise a patterned aperturedweb that forms a first portion and a second, different portion thereof.Aperture patterns in each portion of the patterned apertured web may bethe same, substantially similar, or different. In another instance, anabsorbent article may comprise a patterned apertured web that comprisesa first portion of an absorbent article, and wherein a second portion ofthe absorbent article has graphics, printing, patterned adhesives, orother indicia that forms a pattern that is similar to, substantiallysimilar to, coordinates with, or is different than an aperture patternin the patterned apertured web.

In an instance, a patterned apertured web may have a plurality of zones.A first zone may have at least some apertures having a first angle(central longitudinal axis of aperture vs. MD), first size, and/or firstshape, while a second zone (or third or fourth zone etc.) may haveapertures having a second, different angle (central longitudinal axis ofaperture vs. MD), second, different size, and/or second, differentshape.

Visual Texture

Apertures, patterned apertures, aperture arrays, three-dimensionalelements, printing, patterned adhesives, or any combinations of these“texture elements” may impart a variable visually observed texture in apatterned apertured web. Variations in observable textures have beenextensively studied in the psychological and neurological sciences. Somesmall texture elements are much more readily (“instantly”) detected bythe human visual perception system than others. Most texture patternshaving similar “second order” (iso-dipole) statistics cannot bediscriminated in a brief “flash” observation. However, exceptions tothis (i.e., iso-dipole texture elements that are easily discriminated)have been defined and are known in the literature as “textons”.Patterned apertured webs including texture elements forming textonshapes provide a way to create easily recognizable “zones” on a laminateor in an absorbent article, signaling regions having differentfunctions, and/or providing strong cues as to correct productorientation on a wearer (e.g., front/back). Forms of the patternedapertured webs of the present disclosure may include texture elementsforming texton shapes, including quasi-collinearity, corner features,and closure of local features. A reference is Julesz, B., et al, VisualDiscrimination of Textures with Identical Third-Order Statistics,Biological Cybernetics vol. 31, 1978, pp. 137-140).

Effective Open Area

A patterned apertured web may have an Effective Open Area between about3% to about 50%, about 5% to about 50%, about 5% to about 40%, about 10%to about 40%, about 10% to about 35%, about 10% to about 30%, or about15% to about 30%, specifically reciting all 0.1% increments within thespecified ranges and all ranges formed therein or thereby. All EffectiveOpen Area percents are determined using the Aperture Test describedherein. Patterned apertured webs having a higher Effective Open Area mayhave utility as a topsheet or acquisition layer or system in anabsorbent article (more functional to absorbent bodily exudates), whilepatterned apertured webs having a lower Effective Open Area may haveutility as an outer cover of an absorbent article (more decorative orfor breathability purposes).

Effective Aperture Area

A patterned apertured web may have apertures having an EffectiveAperture Area in the range of about 0.3 mm² to about 15 mm², 0.3 mm² toabout 14 mm², 0.4 mm² to about 12 mm², 0.3 mm² to about 10 mm², 0.5 mm²to about 8 mm², or 1.0 mm² to about 8 mm², specifically reciting all0.05 mm increments within the specified ranges and all ranges formedtherein or thereby. All Effective Aperture Areas are determined usingthe Aperture Test described herein. A plurality of the apertures in apatterned apertured web may be different in Effective Aperture Areas.The Relative Standard Deviation of the Effective Aperture Areas in apatterned apertured web may be at least about 50%, or at least about55%, or at least about 60%, for example.

Aperture Aspect Ratio

The apertures of the patterned apertured webs of the present disclosuremay have an aspect ratio of greater than one, for example, greater thantwo, greater than 3, greater than 5, or greater than 10, but typicallyless than 15, according to the Aperture Test herein. The aperturepatterns in the patterned apertured web may comprise apertures havingmore than one aspect ratio, such as two or more distinct populations orhaving a substantially continuous distribution of aspect ratios having aslope greater than zero. Additionally, the aperture patterns of thepatterned apertured webs may comprise apertures with more than twoeffective aperture areas, either as two or more distinct populations oras a distribution of aperture areas having a slope greater than zero.The Relative Standard Deviation of the aperture aspect ratios in apatterned apertured web may be at least about 30%, at least about 40%,or at least about 45%.

Aperture Density

The apertures of the patterned aperture webs of the present disclosuremay have an Aperture Density, according to the Aperture Test herein, ofat least about 150, at least about 175, at least about 200, or at leastabout 300, for example.

Method

A method of producing a patterned apertured web is provided. The methodmay comprise providing a web having a central longitudinal axis. The webmay comprise a plurality of overbonds extending substantially parallelto, or parallel to, the central longitudinal axis. Substantiallyparallel means +/−5 degrees or +/−3 degrees or less. The method maycomprise conveying the web in a machine direction. The machine directionmay be substantially parallel to, or parallel to, a direction ofextension of the central longitudinal axis of the web. The method maycomprise stretching the web in a cross-machine direction that issubstantially perpendicular (+/−5 degrees or +/−3 degrees or less) tothe machine direction to cause at least some of, most of, or all of, theoverbonds to at least partially rupture, or fully rupture, and at leastpartially form, or form, patterned apertures in the web. At least someof the patterned apertures may have Absolute Feret Angles, according tothe Aperture Test herein, of at least about 10 degrees, at least about15 degrees, at least about 20 degrees, at least about 25 degrees, atleast about 30 degrees, at least about 35 degrees, at least about 40degrees, at least about 45 degrees, or in the range of about 10 degreesto about 45, or about 15 to about 35 degrees, specifically reciting all0.1 degree increments within the specified ranges and all ranges formedtherein or thereby. At least some of the patterned apertures may have anAspect Ratio, according to the Aperture Test herein, of greater thanabout 1.5:1, greater than about 1.8:1, greater than about 2:1, greaterthan about 2.5:1, greater than about 3:1, or in the range of about 1.5:1to about 10:1, about 2:1 to about 6:1, about 2:1 to about 5:1, or about2:1 to about 4:1, specifically reciting all 0.1 increments (e.g., 1.6:1,1.7:1, 1.8:1) within the specified ranges and all ranges formed thereinor thereby. The overbond may be at least partially ruptured, or fullyruptured, to form the patterned apertures using the process illustratedand described with respect to FIGS. 16, 17, and 24-30, for example.

At least some of the patterned apertures may have Absolute Feret Angles,according to the Aperture Test herein, in the range of about 0 degreesto about five degrees, or about 0 degrees (i.e., +/−2 degrees). Thus,some of the patterned apertures may be angled relative to the machinedirection, while others may not. The patterned apertures may comprise afirst plurality of patterned apertures and a second plurality ofpatterned apertures. Central longitudinal axes of the first plurality ofpatterned apertures may extend in a first direction relative to themachine direction. Central longitudinal axes of the second plurality ofapertures may extend in a second, different direction relative to themachine direction. The second different direction may be at least about5 degrees, at least about 10 degrees, at least about 15 degrees, atleast about 20 degrees, at least about 30 degrees, at least about 40degrees, at least about 50 degrees, at least about 60 degrees, at leastabout 70 degrees, at least about 80 degrees, at least about 90 degrees,or in the range of about 10 degrees to about 90 degrees, or about 20degrees to about 70 degrees, specifically reciting all 0.1 degreeincrements within the above-specified ranges and all ranges formedtherein or thereby, different than the first direction. The firstdirection may have a positive slope relative to the machine directionand the second direction may have a negative slope relative to themachine direction. In other instances, the first direction and thesecond direction may both have a positive slope or may both have anegative slope. At least some of the plurality of the overbonds may forma diamond-shaped or diamond-like pattern in the web. Land areas may beformed at least partially around, or fully around, at least some of theplurality of the overbonds or the patterned apertures. At least some ofthe patterned apertures, such as 2 or more, 3 or more, or 4 or more maybe non-homogenous meaning that they are designed to have a differentsize, shape, Absolute Feret Angle, according to the Aperture Testherein, and/or Aspect Ratio, according to the Aperture Test herein.

A method of forming patterned apertures in a web is provided. The methodmay comprise providing a web having a central longitudinal axis,conveying the web in a machine direction that is substantially parallelto the central longitudinal axis, and creating a plurality of overbondsin the web. The overbonds may have central longitudinal axes that aresubstantially parallel to the central longitudinal axis of the web. Themethod may comprise stretching the web in a cross-machine direction thatis substantially perpendicular to, or perpendicular to, the machinedirection to at least partially form, or fully form, patterned aperturesin the web at, at least some of, or most of, or all of, the overbonds.At least some of the patterned apertures may have Absolute Feret Angles,according to the Aperture Test herein, of at least about 20 degrees (andother numbers and ranges set forth above). At least some of thepatterned apertures may have an Aspect Ratio, according to the ApertureTest herein, of greater than about 2:1 (and other numbers and ranges setforth above). At least some of patterned apertures may have AbsoluteFeret Angles, according to the Aperture Test herein, of at least about30 degrees (and other numbers and ranges set forth above). The patternedapertures may comprise a first plurality of patterned apertures and asecond plurality of patterned apertures. Central longitudinal axes ofthe first plurality of patterned apertures may extend in a firstdirection. Central longitudinal axes of the second plurality ofpatterned apertures may extend in a second, different direction. Thesecond different direction may be at least about 10 degrees or at leastabout 30 degrees (and other numbers and ranges set forth above)different than the first direction.

A method of producing a patterned apertured web is provided. The methodmay comprise providing a web having a central longitudinal axis. The webmay comprise a plurality of overbonds extending substantially parallelto, or parallel to, the central longitudinal axis. The method maycomprise conveying the web in a machine direction that is substantiallyparallel to, or parallel to, a direction of extension of the centrallongitudinal axis of the web. The method may comprise stretching the webin a cross-machine direction that is substantially perpendicular to, orperpendicular to, the machine direction to cause at least some of, ormost of, or all of, the overbonds to at least partially rupture, orfully rupture, and at least partially form, or fully form, apertures inthe web. At least some of the apertures have Absolute Feret Angles,according to the Aperture Test herein, that are at least about 25degrees (and other numbers and ranges set forth above). At least some ofthe apertures have an Aspect Ratio, according to the Aperture Testherein, in the range of about 2:1 to about 6:1 (and other ratios andranges as set forth above. At least two, three, four, or five of theapertures may be nonhomogeneous.

Patterned apertured webs having apertures having different AbsoluteFeret Angles may provide liquid bodily exudate handling benefits whenthe patterned apertured webs are used as topsheets in absorbentarticles, for example. For example, fluid run-off may be reduced in thefront or back of the absorbent article when all of the Absolute FeretAngles are not all about 0 degrees, but instead are greater than 0degrees, such as about 15 degrees, about 20 degrees, about 30 degrees,about 45 degrees, or even about 90 degrees, as the apertures can morereadily acquire the liquid bodily exudates. Therefore, it may bedesirable to have apertures having different Absolute Feret Angles tomost effectively acquire liquid bodily exudates running along thesurface of the patterned apertured web and prevent, or at least inhibit,run-off and soiling of garments.

In some example patterned apertured webs of the present disclosure, apattern of overbonds, each of which is oriented solely in the machinedirection, or substantially in the machine direction (i.e., +/−5degrees+/−3 degrees or less from the machine direction), may be used tocreate a patterned apertured web with apertures having Absolute FeretAngles or central longitudinal axes that are not all oriented in themachine direction or, stated another way, that are angled more than 5degrees with respect to the machine direction or have Absolute FeretAngles that are greater than 5 degrees, greater than 10 degrees, greaterthan 15 degrees, greater than 25 degrees, or greater than 30 degrees.Referring to FIG. 53, an example overbond pattern having overbonds “O”oriented solely in the machine direction are illustrated. The overbondpattern of FIG. 53 may be used to produce the patterned apertured web 10of FIG. 53A, for example. The patterned apertured web 10 of FIG. 53A mayhave some apertures 12 having a central longitudinal axis, L, having anangle with respect to the machine direction or an Absolute Feret Anglegreater than 5 degrees. The Absolute Feret Angle may be any of thenumbers or ranges set for the above. Some of the apertures 12 in thepatterned apertured web 10 may also have a central longitudinal axis,L1, that extends parallel to, or substantially parallel to (e.g.,+/−less than 5 degrees), the machine direction or apertures 12 havingAbsolute Feret Angles in the range of about 0 to about 5 degrees. Thecross directional stretching step or steps described herein may be usedto create the apertures and to orient the central longitudinal axes, L,of at least some of the apertures in a direction not parallel to, orsubstantially parallel to, the machine direction. At least some of theapertures in a patterned apertured web having their central longitudinalaxes not parallel to, or substantially parallel to, the machinedirection may have a first plurality of apertures having centrallongitudinal axes extending in a first direction with respect to themachine direction and a second plurality of apertures having centrallongitudinal axes extending at a second, different direction relative tothe machine direction. Those of skill in the art will recognize thatother angles relative to the machine direction are also within the scopeof the present disclosure.

The apertures in a patterned apertured web having a central longitudinalaxis angled with respect to the machine direction and produced bymachine direction overbonds may be more open (i.e., have a lower aspectratio) than they would have been if the overbonds had been oriented atan angle (5 degrees or more) with respect to the machine direction.Overbonds oriented at an angle with respect to the machine directiontypically produce apertures having higher aspect ratios postcross-directional stretching that are less open.

Fused Portions

Referring to FIG. 54, areas surrounding at least a portion of anaperture 12 in a patterned apertured web of the present disclosure maycomprise one or more fused portions 5000. The fused portions 5000 may atleast partially surround the apertures 12, or fully surround theapertures 12. The fused portions 5000 may surround at least 25% of aperimeter of the apertures 12 up to about 100% of the perimeter of theapertures 12. In some instances, the fused portions 5000 may be formedon the lateral sides of the apertures 12 and not on the leading andtrailing edges of the apertures 12 (see MD and CD arrows for referencein FIG. 54). The fused portions 5000 are believed to be formed duringthe overbonding step and are believed to add strength to the patternedapertured webs.

Example Overbond Patterns for Patterned Apertured Webs

Some example schematic representations of additional overbond patternsthat could be used on an overbonding roller, like roller 110 of FIG. 16are illustrated in FIGS. 55-60. Those of skill in the art will recognizethat other suitable overbond patterns are also within the scope of thepresent disclosure, along with variations of the illustrated patterns.

Interaperture Distance and Average Interaperture Distance

The patterned apertured webs or layers thereof may have apertures thathave an Average Interaperture Distance of less than about 3.5 mm, lessthan about 3 mm, less than about 2.5 mm, less than about 2 mm, less thanabout 1.5 mm, less than about 1 mm, in the range of about 1 mm to about3.5 mm, in the range of about 1 mm to about 3 mm, in the range of about1 mm to about 2.5 mm, or in the range of about 3.5 mm to about 10 mm,specifically reciting all 0.1 mm increments within the above-specifiedranges and all ranges formed therein or thereby, according to theAperture Test herein.

A patterned apertured web may have Interaperture Distances, calculatedaccording to the Aperture Test herein. The Interaperture Distances mayhave a distribution having a mean and a median. The mean may be greaterthan, different than, or less than the median. The mean may be greaterthan, different than, or less than the median in the range of about 3%to about 25%, about 4% to about 25%, about 5% to about 20%, about 8% toabout 20%, or about 4% to about 15%, for example, specifically recitingall 0.1% increments within the above-specified ranges and all rangesformed therein or thereby. A first zone of a patterned apertured web mayhave Interaperture Distances. The Interaperture Distances of the firstzone may have a first distribution having a first mean and a firstmedian. The first mean may be greater than, different than, or less thanthe first median by the ranges set forth above in this paragraph. Asecond zone of the patterned apertured web may have InterapertureDistances. The Interaperture Distances of the second zone may have asecond distribution having a second mean and a second median. The secondmean may be greater than, less than, or different than the second medianby the ranges set forth above in this paragraph. A third zone of thepatterned apertured web may have Interaperture Distances. TheInteraperture Distances of the third zone may have a third distributionhaving a third mean and a third median. The third mean may be greaterthan, different than, or less than the third median by the ranges setforth above in this paragraph. The first, second, and third means may bethe same or different. The first, second, and third medians may be thesame or different. The first, second, and third zones may be in atopsheet, a topsheet layer, an acquisition layer, an outer cover, anouter cover layer, or any other component of an absorbent article orother consumer products.

In other instances, a first portion of an absorbent article or otherconsumer product may have a first patterned apertured web that hasInteraperture Distances, according to the Aperture Test herein. TheInteraperture Distances of the first portion have a first distribution.A second portion of an absorbent article or other consumer product mayhave a second patterned apertured web that has Interaperture Distances,according to the Aperture Test herein. The Interaperture Distances ofthe second portion have a second distribution. A third portion of anabsorbent article or other consumer product may have a third patternedapertured web that has Interaperture Distances, according to theAperture Test herein. The Interaperture Distances of the third portionhave a third distribution. The first, second, and third distributionsmay be the same or different. The first distribution may have a firstmean and a first median. The first mean may be greater than, less than,or different than the first median in the range of about 3% to about25%, about 4% to about 25%, about 5% to about 20%, about 8% to about20%, or about 4% to about 15%, for example, specifically reciting all0.1% increments within the above-specified ranges and all ranges formedtherein or thereby. The second distribution may have a second mean and asecond median. The second mean may be greater than, different than, orless than the second median by the ranges set forth above in thisparagraph. The third distribution may have a second mean and a secondmedian. The second mean may be greater than, different than, or lessthan the second median by the ranges set forth above in this paragraph.The first, second, and third means may be the same or different. Thefirst, second, and third medians may be the same or different. TheRelative Standard Deviation of the Interaperture Distances of apatterned apertured web may be at least about 50%, or at least about55%. The Maximum Interaperture Distance in a given patterned aperturedweb may be at least about 8 mm, or at least about 10 mm, for example.

Average Absolute Feret Angle and Absolute Feret Angle

A patterned apertured web may have one or more apertures having anAbsolute Ferret Angle, according to the Aperture Test herein, of atleast about 15 degrees, at least about 18 degrees, at least about 20degrees, at least about 22 degrees, at least about 25 degrees, at leastabout 30 degrees, at least about 35 degrees, at least about 40 degrees,in the range of about 15 degrees to about 80 degrees, in the range ofabout 20 degrees to about 75 degrees, in the range of about 20 degreesto about 70 degrees, or in the range of about 25 degrees to about 65degrees, specifically reciting all 0.1 degrees increments within theabove-specified ranges and all ranges formed therein or thereby.

A patterned apertured web may have a plurality of apertures having anAverage Absolute Ferret Angle, according to the Aperture Test, of atleast about 15 degrees, at least about 18 degrees, at least about 20degrees, at least about 22 degrees, at least about 25 degrees, at leastabout 30 degrees, at least about 35 degrees, at least about 40 degrees,in the range of about 15 degrees to about 80 degrees, in the range ofabout 20 degrees to about 75 degrees, in the range of about 20 degreesto about 70 degrees, or in the range of about 25 degrees to about 65degrees, specifically reciting all 0.1 degrees increments within theabove-specified ranges and all ranges formed therein or thereby. Theseapertures may all be within a single repeat unit of the patternedapertured web. The Relative Standard Deviation of the Absolute FeretAngles in a patterned apertured web may be at least about 30%, or atleast about 40%, or at least about 50%. A repeat unit is an area in apatterned apertured web that can be identified as having a full aperturepattern or array. Multiple repeat units may be present in a patternedapertured web, with one full aperture pattern or array being present ineach repeat unit.

At least two, at least 3, at least 4, at least 5, at least 6, at least7, at least 8, at least 9, or at least 10 of the apertures in apatterned apertured web, or a repeat unit of a patterned apertured web,may each have a different Absolute Feret Angle, according to theAperture Test herein. In other instances, some of the apertures may haveAbsolute Feret Angles that are the same, while other of the aperturesmay have Absolute Feret Angles that are different. In addition to havingdifferent Absolute Feret Angles, the at least two, at least 3, at least4, at least 5, at least 6, at least 7, at least 8, at least 9, or atleast 10 apertures may have different sizes and/or shapes. At least someof the at least two, at least 3, at least 4, at least 5, at least 6, atleast 7, at least 8, at least 9, or at least 10 apertures may also havethe same size and/or shape, while having different Absolute FeretAngles. The Absolute Feret Angles of at least some of the apertureswithin a repeat unit may differ by at least about 5 degrees, at leastabout 10 degrees, at least about 15, degrees, at least about 20 degrees,at least about 25 degrees, or at least about 30 degrees, for example.

Pre-Strained Laminates

One or more layers of a laminate may comprise one or more pre-strainedlayers. The pre-strained layers may be apertured or non-apertured. Otherlayers of the laminate may be apertured or non-apertured. The aperturedlayer(s) may have uniformly sized and spaced apertures or may havenonhomogeneous patterned apertures, such as the various patternedaperture patterns described herein. The patterned apertures may have anyof the features or parameters described herein. The layers may comprisenonwovens, films, cellulosic webs, foams, or other materials. In someinstances, non-apertured layers may comprise a plurality of overbondsarranged in a pattern. The pre-strained layer or layers may be joined tothe non-pre-strained layer or layers to form a three-dimensionallaminate upon the release of the pre-strain. The pre-strained layers maybe pre-strained in an amount of about 5% of their length or width toabout 40% of their length or width or about 5% of their length or widthto about 20% of their length or width, specifically reciting all 0.1%increments within the specified ranges and all ranges formed therein orthereby. In other instances, the pre-strained layers may be pre-strainedin an amount of about 5%, about 10%, about 15%, or about 20%, forexample. The pre-strained layer should at least partially recover afterbeing joined to a non-pre-strained layer to create three-dimensionalfeatures in the non-pre-strained layer.

In an instance, referring to FIG. 61, an example schematiccross-sectional view of a laminate 7000 may comprise a first layer 7002and a second layer 7004. The second layer 7004 was pre-strained prior tobeing joined to the first layer 7002, thereby resulting in thethree-dimensional features 7006 in the first layer 7002 upon relaxationof the laminate. Either or both of the first layer 7002 and the secondlayer 7004 may comprise uniform and homogeneous apertures,nonhomogeneous patterns of apertures, overbonds (either homogeneous ornon-homogeneous), or embossments. The first layer 7002 and/or the secondlayer 7004 (or any additional layer) may also comprise indicia 7008. Theindicia 7008 may comprise a patterned adhesive, a patterned pigmentedadhesive, a printed ink, or a printed pigmented ink, for example. Theindicia 7008 may be at least partially visible through apertures orpatterned apertures in one layer of the laminate 7000 or through anon-apertured layer of the laminate 7000. The indicia 7008 may be adifferent color than the first layer 7002 and/or the second layer 7004.For example, the indicia may be teal and the first and second layers maybe white. The first and second layers 7002 and 7004 may also havedifferent or the same colors or opacities. Although the example laminate7000 is described in a two layer form, it will be understood thatlaminates having any suitable number of layers are within the scope ofthe present disclosure. In such instances, any suitable number of thelayers may comprise indicia, apertures, patterned apertures,embossments, overbonds, and/or may be pre-strained. As an example, athird layer 7010, illustrated in dash, may be joined to the first layer7002. The third layer 7010 may also be joined to the second layer 7004,for example. The third layer 7010 may be apertured or non-apertured.

An example of a top view of a pre-strained laminate is illustrated inFIG. 62. A cross-sectional view of the pre-strained laminate of FIG. 62is illustrated in FIG. 63. The laminate has apertured areas 7012 andnon-apertured areas 7014. The laminate has one pre-strained layer 7016and one non-pre-strained layer 7018. Upon release of the pre-strainforce of the pre-strained layer 7016, three dimensional features 7020are formed in the non-pre-strained layer 7018.

Again referring to FIG. 61 the first layer 7002 having thethree-dimensional features 7006 may have a greater path length than thesecond layer 7004 that was pre-strained. The path length is the distancetraveled between a first edge 7001 of the material and a second edge7003 of the material (following the material from the left to the rightin FIG. 61). If the third layer 7010 is attached to the first layer 7002or to the second layer 7004, the third layer may have a different pathlength or the same path length as the first layer 7002 or the secondlayer 7004.

In an instance, both the first and second layers 7002 and 7004 may eachhave a plurality of apertures or patterned apertures. At least some ofthe apertures in the first layer 7002 may at least partially, or fully,align with at least some of the apertures in the second layer 7004. Inother instances, all of, or most of, the apertures may align or at leastpartially align. In such configurations, portions of, or all of,perimeters of at least some apertures in the first layer 7002 may bebonded (e.g., mechanically or adhesively) to portions of, or all of,perimeters of at least some apertures in the second layer 7004. In otherconfigurations, the first and second layers 7002 and 7004 may be joinedby a plurality of and/or a pattern of mechanical or adhesive bonds.

The first layer 7002 may be formed of a different material than thesecond layer 7004 and/or the third layer 7010. In an example, the firstlayer 7002 may be formed of a first nonwoven material and the secondand/or third layers 7004, 7010 may be formed of a different nonwovenmaterial or other material, such as a film, for example.

The patterned apertures in any of the layers may have the Absolute FeretAngles, the Average Absolute Feret Angles, the Interaperture Distances,Effective Aperture Areas, and/or the Average Interaperture Distancesdescribed herein. Further, any of the layers may have the Effective OpenAreas specified herein, such as in the range of about 5% to about 50%.

Absorbent articles may comprise one or more of these pre-strainedlaminates. Example absorbent articles, as described above, may comprisea liquid permeable topsheet, a liquid impermeable backsheet, and outercover nonwoven material, and an absorbent core, among other features.The pre-strained laminates may be used as topsheets, outer covers, outercover nonwoven material/backsheet laminates, portions of garment-facingsurfaces of the absorbent articles, portions of wearer-facing surfacesof the absorbent articles, portions of belts, hip areas, waist areas,and/or portions of barrier leg cuffs, for example. These pre-strainedlaminates may also be used in cleaning substrates, dusting substrates,wipes, medical substrates, and/or any other suitable products orconsumer products, for example.

Some examples of pre-strained laminates are illustrated below.

The materials used in Charts 1 and 2 are specified below.

Material A: 25 gsm spunbond nonwoven material comprising 50/50 PE/PPsheath/core bicomponent fibers having an average fiber size of 2.8denier per filament, available from Fitesa Nonwovens in Washougal, Wash.

Material B: 24 gsm carded, through-air bonded nonwoven materialcomprising 2.0 dpf PE/PET fibers, available from Xiamen YanjanIndustries, Inc.

In all instances in Charts 1 and 2 below, Layer 2 was pre-strained inthe machine direction by the % shown and then the two layers wereoverbonded together, using the overbonding process described herein withrespect to FIG. 16. The pre-strain force was applied by decreasing thespeed of an infeed roll by 0% (i.e., no pre-strain), 5%, 10%, or 15%(according to the Charts) relative to the speed of the rolls 112 and 114of FIG. 16. The pre-strain in Layer 2 was then released. Exampleswithout the overbonds ruptured are Examples 1-8 and FIGS. 64-67.Examples with the overbonds ruptures are Examples 9-16 and FIGS. 68-71.In the latter, the overbonds were ruptured to form apertures in bothlayers using the steps and equipment 132 and 132′ described herein withrespect to FIG. 15 (with additional details described in view of FIGS.23-29). For Examples 9-16, the depth of engagement (see e.g., FIG. 24)was 0.065 inches and the line speed was 1,000 feet per minute.

As the amount of pre-strain on Layer 2 increases, the caliper of theresultant pre-strained laminate may also increase, by an amount than isgreater than the increase in basis weight would predict. The examplesubstrates of FIGS. 65, 67, 69, and 71 with a pre-strained layer showsignificant puckering or three-dimensionality as compared to thenon-pre-strained examples of FIGS. 64, 66, 68, and 70.

Chart 1—Overbond Only, No Apertures

Total Layer Basis Normalized 2 % Weight Caliper Layer (pre- Pre- Caliper(BW) (Caliper/ Example # 1 strain) Strain (mm) (gsm) BW) 1 (FIG. 64) A A0 0.45 51.8 0.009 2 A A 5 0.66 56.0 0.012 3 (FIG. 65) A A 10 1.01 61.60.016 4 A A 15 1.38 69.0 0.020 5 (FIG. 66) B A 0 0.57 49.3 0.012 6 B A 50.89 52.7 0.017 7 (FIG. 67) B A 10 1.31 62.6 0.021 8 B A 15 1.53 68.50.022Chart 2—Overbond and Apertures

Layer 2 % Pre- Caliper Example # Layer 1 (pre-strain) Strain (mm)  9(FIG. 68) A A 0 0.66 10 A A 5 0.69 11 (FIG. 69) A A 10 0.70 12 A A 150.76 13 (FIG. 70) B A 0 0.81 14 B A 5 0.92 15 (FIG. 71) B A 10 0.95 16 BA 15 1.01

Various method of producing pre-strained laminates will now bediscussed. For example, two non-apertured layers may be provided. Onelayer may be pre-strained in the CD or MD direction. The layers may thenbe overbonded (see e.g., FIG. 16 for overbonding and associateddisclosure) to join them together, or joined together and thenoverbonded. The pre-strain force may then be released to create aplurality of three-dimensional features in the non-pre-strained layer orin both layers. Optionally, at least some of, most of, or all of theoverbonds may then be ruptured to create apertures in the first andsecond layers. Such rupturing may be done by stretching the first andsecond layers in the CD or MD direction (see e.g., FIGS. 23-29 forexample overbond rupturing). In some instances, the pre-strain force maynot be released until the apertures are ruptured. At least a third layermay also be combined into the laminate. The at least third layer may beapertured or non-apertured, pre-strained, or non-pre-strained. At leastone of the layers may be formed of a different material than theremaining layers (e.g., film/nonwoven, first nonwoven/second nonwoven,or first film/second film).

In an instance, one apertured layer may be combined with onenon-apertured layer, or two apertured layers may be combined, usingmechanical or adhesive bonding. The apertures may be formed in the layeror layers using any suitable aperturing technique, such as needlepunching, for example. Either of the layers may be pre-strained prior tojoining the layers. Upon release of the pre-strain force,three-dimensional features may be formed in the layer that was notpre-strained, or in both layers. At least a third layer may also becombined into the laminate. The at least third layer may be apertured ornon-apertured, pre-strained or non-pre-strained. At least one of thelayers may be formed of a different material than the remaining layers(e.g., film/nonwoven, first nonwoven/second nonwoven, or firstfilm/second film).

In an instance, one overbonded layer may be combined with onenon-apertured or apertured layer, or two overbonded layers may becombined, using mechanical or adhesive bonding. Either of the layers maybe pre-strained prior to joining the layers. Upon release of thepre-strain force, three-dimensional features may be formed in the layerthat was not pre-strained, or in both layers. At least a third layer mayalso be combined into a laminate. The at least third layer may beoverbonded or non-overbonded, apertured or non-apertured, pre-strainedor non-pre-strained. At least one of the layers may be formed of adifferent material than the remaining layers (e.g., film/nonwoven, firstnonwoven/second nonwoven, or first film/second film).

In an instance, a method of forming a three-dimensional laminate for anabsorbent article is provided. The method may comprise providing a firstlayer and a second layer (and optionally additional layers). The firstand second layers may be the same or different. For example, the layersmay comprise the same nonwoven materials, the same film materials, twodifferent nonwoven materials, two different film materials, or a filmmaterial and a nonwoven material. In some instances, any of these layersmay be apertured or non-apertured, overbonded or non-overbonded. Theapertures patterns or overbonds patterns may be homogeneous ornon-homogeneous. The method may comprise applying a pre-strain force tothe first or second layers. The pre-strain force may be applied in anysuitable direction, such as substantially in the machine direction orsubstantially in the cross-machine direction, for example. The layersmay then be joined by adhesive or mechanical bonding, or other suitablemethods of joining layers. If at least one of the first or second layersis not apertured or overbonded, the joining step may comprise anoverbonding step (see e.g., FIG. 16 for overbonding as associateddisclosure) or embossing. The first and second layers may be joined toeach other while the first or second layer remains in a pre-strainedstate or condition. Suitable adhesives, patterned adhesive, pigmentedpatterned adhesives, pigmented printed inks, or printed inks may beapplied to the first or second layers pre joining or post-joining, ifdesired. If an overbonding step is used, the layers, post-joining, maybe stretched in a suitable direction, such as substantially in thecross-machine direction or substantially in the machine direction to atleast partially rupture, or fully rupture at least some of, most of, orall of the overbonds to thereby at least partially form, or formapertures in the layers (see e.g., FIGS. 23-29 for such rupturing). Thepre-strain force may then be released to form a plurality ofthree-dimensional features in the laminate. The plurality ofthree-dimensional features may be formed in the non-pre-strained layeror in both of the layers (including the pre-strained layer).

Any of the laminates with at least one layer pre-strained may be free ofelastic strands or elastic films.

The methods may comprise applying a pre-strain force to one of thelayers (pre-layer joining) in a substantially machine direction, amachine direction, or other direction. The pre-strain force causes thelayer being pre-strained to elongate in the direction the pre-strainforce is being applied by at least 5%, at least 10%, at least 15%, atleast 20%, in the range of about 5% to about 40%, or in the range ofabout 5% to about 20%, specifically reciting all 0.1% increments withinthe specified ranges and all ranges formed therein or thereby. Thepre-strain force may be applied by suppling a continuous web ofpre-strained laminate where an infeed roll is rotating at a slower speedthan overbonding rolls or an output roll.

If a layer, or more than one layer, of the pre-strained laminate has aplurality of overbonds, the overbonds may comprise a first overbond, asecond overbond, and at least a third overbond. The first, second, andat least third overbonds may all be different in size, shape, feretangle, and/or orientation. Alternatively, at least two of the first,second, and third overbonds may be different in size, shape, feretangle, and/or orientation.

One or more layers of a laminate (pre-strained layer or no pre-strainedlayer) may have a first overbond having a central longitudinal axisextending in a first direction, a second overbond having a centrallongitudinal axis extending in a second direction, and a third overbondhaving a central longitudinal axis extending in a third direction. Atleast two of, or all of the first, second, and third directions may bedifferent. At least two of, or all of, the first, second, and thirddirections may be at least about 5 degrees, at least about 10 degrees,at least about 15 degrees, at least about 20 degrees, apart from eachother. In other instances, at least two of, or all of, the first,second, and third directions may be different from each other in therange of about 5 degrees to about 40 degrees, about 5 degrees to about30 degrees, or about 10 degrees to about 25 degrees, specificallyreciting all 0.1 degree increments within the specified ranges and allranges formed therein or thereby. More than three overbonds havingcentral longitudinal axes may also be provided. The central longitudinalaxes of the more than three overbonds may also extend in differentdirections than the first, second, and third central longitudinal axes,as described in this paragraph.

Another method of forming a three-dimensional laminate for an absorbentarticle is provided. The method may comprise providing a first layer andproviding a separate, second layer. The layers may be the same ordifferent in material, basis weight, and/or properties, for example. Themethod may comprise applying a pre-strain force to the first layer or tothe second layer and overbonding the first layer and the second layerwhile the first layer or the second layer is in a pre-strained conditionto join the first layer and the second layer. The method may furthercomprise releasing the pre-strain force to form the three-dimensionallaminate and three-dimensional features in the non-pre-strained layer.Before or after the pre-strain force is released, the method maycomprise stretching the first and second layers to cause at least someof, most of, or all of the overbonds to at least partially rupture andat least partially form, or form, apertures in the first and secondlayers. This stretching may be substantially (e.g., +/−1 degree, +/−3degrees, or +/−5 degrees) in the cross-machine direction, while thepre-strain force may be substantially in the machine direction (e.g.,+/−1 degree, +/−3 degrees, or +/−5 degrees). In other instances, thestretching may be substantially in the machine direction, while thepre-strain force may be substantially in the cross-machine direction.

Another method of forming a three-dimensional laminate for an absorbentarticle is provided. The method may comprise providing a nonwoven firstlayer and providing a separate, nonwoven second layer. The method maycomprise applying a pre-strain force substantially in the machinedirection to the first nonwoven layer or to the second nonwoven layerand overbonding the first layer and the second layer while the firstlayer or the second layer is in a pre-strained condition to join thefirst layer and the second layer. The method may comprise stretching thefirst and second nonwoven layers in a substantially cross-machinedirection to cause at least some of, most of, or all of the overbonds toat least partially rupture and at least partially form, or formapertures in the first and second nonwoven layers. The method maycomprise releasing the pre-strain force to form the three-dimensionallaminate and form three-dimensional features in the non-pre-strainedlayer. The three-dimensional laminate may be free of elastic strands orelastic films.

Garment-Facing Layer/Garment-Facing Laminate

Absorbent article of the present disclosure may comprise agarment-facing layer or garment facing laminates comprising at least oneapertured or patterned apertured layer. The absorbent articles maycomprise a liquid permeable topsheet on a wearer-facing side of theabsorbent article and a garment-facing laminate or a garment-facinglayer on a garment-facing side of the absorbent article. Thegarment-facing laminate may comprise a first layer or a first nonwovenlayer and a second layer joined to the nonwoven layer. The first layeror the first nonwoven layer may comprise a plurality of apertures. Insome instances, at least 3, at least 5, or at least 10 of the aperturesin a repeat unit have one or more of a different size, a differentshape, or a different Absolute Feret Angle, according to the ApertureTest herein. At least 3, at least 5, or at least 10 of the plurality ofapertures in the first nonwoven layer may be non-homogeneous apertureswithin the repeat unit. The garment-facing layer may only comprise asingle layer having the features of the first layer or first nonwovenlayer of the garment-facing laminate. The absorbent article may comprisean absorbent core that is disposed at least partially intermediate theliquid permeable topsheet and the garment-facing laminate or thegarment-facing layer. Either of the first or second layers of thegarment-facing laminate may be pre-strained as described herein tocreate three-dimensional features in the non-pre-strained layer or inboth layers. The first or second layer that is pre-strained may be freeof apertures.

The second layer of the garment-facing laminate may be a second nonwovenlayer. The second nonwoven layer may be positioned on the outermostsurface of the garment-facing surface or intermediate the first nonwovenlayer and a liquid impermeable backsheet. If the second nonwoven layeris positioned on the outermost surface, the first nonwoven layercomprising the apertures or patterned apertures may be visible throughthe second nonwoven layer. In an instance, the second nonwoven layer maycomprise apertures or patterned apertures, as the patterned aperturedare described herein. The second nonwoven layer may also benon-apertured. In other instances, the second layer of thegarment-facing laminate may comprise a liquid impermeable backsheetfilm. A patterned adhesive, a pigmented patterned adhesive, a printedink, or a pigmented printed ink (together “indicia”) may be on thebacksheet film such that this indicia is visible through the firstand/or second layers and/or through the apertures or the patternedapertures in one of the layers. This indicia may also be on the firstnonwoven layer or the second nonwoven layer in other instances. In aninstance, a first portion of the indicia may be on the first nonwovenlayer and a second portion of the indicia may be on the second layer.

The first nonwoven layer may be joined to the second layer or the secondnonwoven layer by a patterned of mechanical or adhesive bonds. In otherinstances, the first nonwoven layer may be joined to the second layer orthe second nonwoven layer by a patterned adhesive or a pigmentedpatterned adhesive. The patterned adhesive or pigmented patternedadhesive may have a first color that is different than the color of thefirst nonwoven layer or the second layer or the nonwoven layer. Forexample, the adhesive may be teal, while the first and second layers arewhite. The first and second layers may also have colors that aredifferent.

FIGS. 72-75 illustrate example layering of garment-facing laminates. Inthe example of FIG. 72, a first layer 8002 may be a liquid impermeablebacksheet, a second layer 8004 may be a material, such as a nonwovenmaterial, that is apertured or non-apertured, and a third layer 8006 maybe a material, such as a nonwoven material, that is apertured ornon-apertured. If any of the layers are non-apertured, they may compriseembossments or overbonds. One or more of layers 8002, 8004, and 8006 maybe pre-strained prior to being joined to the other layers. In someinstances, the first layer 8002 may also be a nonwoven material. Any orall of the layers may be apertured or have patterned apertures. In someinstances, especially in cases where the first layer 8002 is a liquidimpervious backsheet film, the second layer 8004 and/or the third layer8006 may be apertured or have patterned apertures. In other instances,only one of the second layer 8004 and the third layers 8006 may haveapertures or patterned apertures, with the other layer beingnon-apertured. In an instance, it may be desirable to have only thesecond layer 8004 have apertures or patterned apertures with the thirdlayer 8006 being non-apertured to provide an absorbent article with asmooth garment-facing surface. Layer 8006 may form a portion of agarment-facing surface of an absorbent article.

FIG. 73 illustrates the garment-facing laminate of FIG. 72, but with anindicia 8008 positioned on one of the layers; in the example, the firstlayer 8002 or the second layer 8004. The indicia 8008 may also bepositioned intermediate the first and second layers 8002 and 8004. Theindicia 8008 may be a patterned adhesive, a pigmented patternedadhesive, a printed ink, and/or a pigmented printed ink, for example. Asshown in the example of FIG. 74, a first indicia 8008 may be positionedon the first and second layers 8002 and 8004, or may be positionedintermediate the first and second layers 8002 and 8004. A second indicia8008′ may be positioned on the second and third layers 8004 and 8006, ormay be positioned intermediate the second and third layers 8004 and8006. The second indicia 8008′ may be a patterned adhesive, a pigmentedpatterned adhesive, a printed ink, and/or a pigmented printed ink. Insome instances, only the second indicia may be provided. The firstindicia 8008 may be the same as or different than the second indicia8008′. In FIGS. 73 and 74, the first, second, and third layers 8002,8004, and 8006 may be the same as described with respect to FIG. 72. Iftwo or more nonwoven materials are provided as two or more of thelayers, the nonwoven materials may be the same or different (i.e.,different in basis weight, material, methods of manufacture, properties,effective open area). The third layer 8006 may form a portion of agarment-facing surface of an absorbent article.

FIG. 75 illustrates a two layer garment-facing laminate. The first layer8002 and the second layer 8004 may be the same or different. At leastone of the layers may be a nonwoven material. In some instances, thefirst layer 8002 may comprise a liquid impermeable backsheet, while thesecond layer 8004 may comprise a garment-facing surface of an absorbentarticle. In such an instance, the first layer 8002 may be non-apertured,while the second layer 8004 may be apertured, have patterned apertures,or comprise a plurality of overbonds or embossments. Either of the firstand second layers 8002 and 8004 may be pre-strained prior to beingjoined together to create a three-dimensional laminate. An indicia maybe positioned on the first or second layers 8002 or 8004, or may beplaced intermediate the first and second layers 8002 or 8004. Theindicia may be the same as described above with respect to FIG. 73.

The plurality of apertures, patterned apertures, overbonds, orembossments in the first nonwoven layer or the second layer or secondnonwoven layer may have a first pattern in a first area and a second,different pattern in a second, different area. The first area maycomprise one or more of a waist region, a hip region, a belt portion, acrotch region, a front region, a back region, and/or a buttocks region.The second area may comprise a different one or more of the waistregion, the hip region, the belt portion, the crotch region, the frontregion, the back region, and/or the buttocks region. The first patternmay different from the second, different pattern in size and shape,shape and frequency, or size and frequency, for example.

Referring to FIGS. 76 and 77, example garment-facing laminates orgarment-facing layers on an absorbent article 8010 are illustrated. Thegarment-facing laminates or layers may be the same as described above inconstruction, but may have different zones. The absorbent articles 8010may have a first zone 8012, a second zone 8014, and a third zone 8016.The first and second zones 8012, 8014 may form waist or hip portions (orfront or rear regions) of the absorbent article 8010, while the thirdzone 8016 may form a crotch and/or buttocks portion of the absorbentarticle 8010. Any suitable number of zones may also be provided in agarment-facing laminate or layer. At least some of the zones 8012, 8014,8016 may have apertures or patterned apertures. In some instances, twoor more of the zones 8012, 8014, and 8016, or portions thereof, may haveapertures or patterned apertures. In still other instances, one or morezones may have apertures and other zones may have patterned apertures.In yet other instances, one more zones may have overbonds that are notruptured or may have overbonds that are partially ruptured, as will bedescribed in further detail below. One or more of the zones may compriseembossments. The apertures or patterned apertures may be the same ordifferent in different zones. In an instance, the first and second zones8012 and 8014 may have the same pattern of apertures or patternedapertures, overbonds, or embossments, while the third zones 8016 mayhave a different pattern of apertures or patterned apertures, overbonds,or embossments. Any of the zones may also comprise indicia as describedherein. The indicia may be the same or different in various zones.

FIG. 78 illustrates an example absorbent article 8010′ with a first zone8012′, a second zone 8014′, a third zone 8016′, and fourth zone 8018.Any of the first, second, third, and fourth zones 8012′, 8014′, 8016′,and 8018 may be apertured, have patterned apertures, and/or compriseoverbonds and/or embossments. The apertures, patterned apertures,overbonds, and/or embossments may be the same or different in thevarious zones. In an instance, at least two zones may have the samepattern of apertures, patterned apertures, overbonds and/or embossments.Any of the zones may also comprise indicia as described herein. In aninstance, the first and second zones 8012′ and 8014′ may have the samepattern of apertures, patterned apertures, embossments, and/oroverbonds, while the third zone 8016′ or the fourth zone 8018 may have adifferent pattern of apertures, patterned apertures, embossments, and/oroverbonds.

FIG. 79 is another example of an absorbent article 8020 with zones in agarment-facing layer or laminate. A first zone 8022 and a second zone8024 comprise a plurality of apertures 8026 or patterned apertures,while a third zone 8029 comprises a pattern of unopened overbonds 8028or embossments. Stated another way, the first zone 8022 and the secondzone 8024 comprise a plurality of ruptured overbonds 8026, while thethird zone 8029 comprises a plurality of unruptured overbonds 8028. Tocreate such a structure, a material may be overbonded and then certainregions (e.g., the first and second zones 8022 and 8024) may bestretched (e.g., in the cross-machine direction) to at least partially,or fully, rupture the overbonds, with other regions not being stretched(e.g., the third zone 8029). In such a configuration, the garment-facinglayer or laminate may signify that the waist, hip, or belt portions(i.e., the first and second zones 8022 and 8024 (with apertures orpatterned apertures)) are breathable, while the third zone 8029 (withonly overbonds or embossing) is designed for absorbency and/orperformance. Ruptured overbonds (or apertures) and unruptured overbondsmay be positioned in any suitable zones.

FIG. 80 is a photograph of a nonwoven material or laminate with rupturedoverbonds forming apertures in a first section (or zone) 8030 (leftside) and unruptured overbonds in a second section 8032 (or zone) (rightside). FIG. 80 also illustrates a third, transition section 8034positioned intermediate the first section 8030 and the second section8032. In the third, transition section 8034, at least some of theoverbonds are partially ruptured. Such a material may be used as aportion of the garment-facing laminate of FIG. 79.

FIG. 81 is a photograph of a nonwoven laminate with overbonds orembossments in a first section 8036. The first section (or zone) 8036may also have a layer that was pre-strained prior to being joined toanother layer, thereby producing the three-dimensional features. Asecond section (or zone) 8038 may comprise a plurality of apertures or aplurality of patterned apertures with or without a pre-strained layer.The first section 8036 may represent a first zone in a garment-facinglaminate and the second section 8038 may represent a second zone in thegarment-facing laminate.

An absorbent article may comprise a liquid permeable topsheet on awearer-facing side of the absorbent article and a garment-facinglaminate on a garment-facing side of the absorbent article. Thegarment-facing laminate may comprise a first layer or a first nonwovenlayer and a second layer or a second nonwoven layer joined to the firstlayer when the first layer or the second layer is in a pre-strainedcondition and when the other of the first layer or the first nonwovenlayer or the second layer or the second nonwoven layer is in anon-pre-strained condition to form a three-dimensional material. Detailsof the pre-strained layers and laminates comprising a pre-strained layerare described above. The first nonwoven layer may comprise a pluralityof apertures or a plurality of patterned apertures as described herein.At least 3, at least 5, or at least 10 of the apertures may benonhomogeneous apertures. The second layer may comprise a film or maycomprise a backsheet film. The laminate may comprise one or morepatterned adhesives and/or printed inks, as described herein. Theabsorbent article may comprise an absorbent core is disposed at leastpartially intermediate the liquid permeable topsheet and thegarment-facing laminate.

An absorbent article may comprise a liquid permeable topsheet on awearer-facing side of the absorbent article and a garment-facing layeron a garment-facing side of the absorbent article. The garment-facinglayer may comprise a nonwoven material. The garment-facing layer maycomprise a first zone comprising a plurality of overbonds and a secondzone comprising a plurality of apertures or patterned apertures. Thesecond zone may at least partially form a waist region, hip region, orbelt portion, of the absorbent article and the second zone may at leastpartially form a crotch region of the absorbent article. At least 3, atleast 5, or at least 10 of the plurality of apertures in a repeat unitmay have a different size, a different shape, and/or a differentAbsolute Feret Angle, according to the Aperture Test herein. Theabsorbent article may comprise a liquid impermeable backsheet and anabsorbent core is disposed at least partially intermediate the liquidpermeable topsheet and the backsheet.

FIG. 82 is an example patterned apertured web 9000 with patternedapertures 9002 in a central region 9004 thereof and with embossed areas9006 in outer portions 9008 thereof. The patterned apertured web 9000may be used in a feminine hygiene product, as a topsheet, for example,or may be used in other absorbent articles.

FIG. 83 is another example patterned apertured web 9010.

Moiré Effect Laminates and Methods for Making the Same

The present disclosure also envisions laminates that provide a moiréeffect. The moiré effect is a visual image that is evident when onepattern in a first material is superimposed over another pattern in asecond material while one pattern is displaced or moved relative to theother pattern. More than two materials may also be used, optionally withadditional patterns. Providing the moiré effect in various layers ofconsumer products or absorbent articles is highly consumer desiredbecause of the interesting appearance of the product or article. In anabsorbent article context, providing the moiré effect may provide theconsumer with the impressions of depth, absorbency, quality, improvedwicking, and/or and air flow.

Some examples of patterned apertured nonwoven materials providing themoiré effect are illustrated in FIGS. 84-87. In FIG. 84, a first layer1100 is in a first position relative to the second layer 1102. The firstlayer 1100 has a plurality of patterned apertures 1104 (as describedherein) and the second layer 1102 has a plurality of uniformly spacedand homogeneous apertures 1106. FIG. 85 illustrates the first layer 1100in a second position relative to the second layer 1102. FIG. 86illustrates the first layer 1100 in a third position relative to thesecond layer 1102. FIG. 87 illustrates the first layer 1100 in a fourthposition relative to the second layer 1102. When viewing FIGS. 84-87together, the moiré effect is illustrated. This may be accomplished byhaving non-bonded spans between the first and second layers 1100 and1102. By having non-bonded spans in the first and second layers, thefirst and second layers may move relative to each other, even when thefirst and second layers are at least intermittently joined together intoa laminate. Even if the first and second layers do not move relative toeach other, the moiré effect may appear as the viewer moves relative tothe laminate. FIGS. 84-87 are merely examples of the moiré effect, andfurther forms are discussed below.

A moiré effect laminate may have two or more layers. A first layer maycomprise a nonwoven, a cellulosic material, a coform material, a woven,a film, any other suitable material, or combinations thereof. A secondlayer may also comprise a nonwoven, a cellulosic material, a coformmaterial, a woven a film, any other suitable material, or combinationsthereof. The first layer or the second layer may comprise apertures(uniform and homogenous) or patterned apertures as described herein. Inother instances, only one of the layers may comprise apertures orpatterned apertures. In still other instances, neither of the layers maycomprise apertures or patterned apertures.

One of the layers may comprise a plurality of lower opacity zones in apattern positioned within a higher opacity zone. Stated another way, amaterial having a first opacity (higher opacity) may have certain zonesthat have a reduced opacity (lower opacity). The lower opacity zonesshould have an area of at least about 1 mm², at least about 2 mm², atleast about 3 mm², at least about 4 mm², at least about 5 mm², at leastabout 6 mm², at least about 7 mm², at least about 8 mm², or in the rangeof about 1 mm² to about 20 mm², about 1 mm² to about 15 mm², about 2 mm²to about 10 mm², specifically reciting all 0.1 mm² increments within thespecified ranges and all ranges formed therein or thereby. These loweropacity zones, in some instances, may be at least partially, or fully,formed by apertures. The lower opacity zones positioned within a higheropacity zone may enable viewing a portion of a pattern behind thematerial with the lower opacity zones. Stated another way, the loweropacity zones essentially create “windows” in the material, therebyallowing a pattern behind the material to be at least partially visible.

The higher opacity zone may have an opacity of at least about 1.1 times,at least about 1.5 times, at least about 2 times, at least about 2.5times, or at least about 3 times greater than the opacity of the loweropacity zones, according to the Opacity Test herein. Alternatively, thehigher opacity zone may have an opacity in the range of about 1.1 timesto about 5 times greater than the lower opacity zones, according to theOpacity Test herein, specifically reciting all 0.1 increments within thespecified range and all ranges formed therein. Also, the higher opacityzone may have an opacity that is at least about 3 percentage points, atleast about 5 percentage points, at least about 10 percentage points, atleast about 15 percentage points, at least about 20 percentage points,or at least about 25 percentage points greater than an opacity of thelower opacity zones, according to the Opacity Test herein.Alternatively, the higher opacity zone may have an opacity that is inthe range of about 3 percentage points to about 20 percentage pointsgreater than the opacity of the lower opacity zones, specificallyreciting all 0.1 percentage point increments within the specified rangesan all ranges formed therein, according to the Opacity Test herein. Ifthe lower opacity zones are apertures, their opacity would be 0% orabout 0%, or about 0% to 5%, specifically reciting all 0.1% incrementswithin the specified range and all ranges formed therein, according tothe Opacity Test herein.

The higher opacity zone may have a light transmission of at least about1.1 times, at least about 1.5 times, at least about 2 times, at leastabout 2.5 times, or at least about 3 times less than the lighttransmission of the lower opacity zones, according to the LightTransmission Test herein. Alternatively, the higher opacity zone mayhave a light transmission in the range of about 1.1 times to about 5times less than the lower opacity zones, according to the LightTransmission Test herein, specifically reciting all 0.1 incrementswithin the specified range and all ranges formed therein. Also, thehigher opacity zone may have a light transmission that is at least about3 percentage points, at least about 5 percentage points, at least about10 percentage points, at least about 15 percentage points, at leastabout 20 percentage points, or at least about 25 percentage points lessthan a light transmission of the lower opacity zones, according to theLight Transmission Test herein. Alternatively, the higher opacity zonemay have a light transmission that is in the range of about 3 percentagepoints to about 20 percentage points less than the light transmission ofthe lower opacity zones, according to the Light Transmission Testherein. If the lower opacity zones are apertures, their lighttransmission would be about 95-100%, specifically reciting all 0.1%increments within the specified range and all ranges formed therein,according to the Light Transmission Test herein.

The layers of the moiré effect laminate may comprise the same materialsor different materials. By different, the layers could be different inbasis weight, opacity, fiber composition, fiber type, fiber size, methodof production, caliper, and/or color, for example. In some instances, afirst layer may be a nonwoven material and a second layer may be adifferent type of nonwoven material or a film.

In some instances, a first pattern in a first layer of a moiré effectlaminate may be a printed pattern, a patterned adhesive, a pattern ofhomogeneous and uniform apertures, patterned apertures (as describedherein), lower opacity zones positioned in a higher opacity zone, and/ora pattern of embossments. Likewise, a second pattern in a second layerof a moiré effect laminate may be a printed pattern, a patternedadhesive, a pattern of homogeneous and uniform apertures, patternedapertures, lower opacity zones positioned in a higher opacity zone, apattern of embossments, or combinations thereof. The first and secondpatterns, in the first and second layers, respectively, may be the sameor different, in size, scale, shape, area, color, and/or orientation,for example. As a further example, a first pattern in a first layer maycomprise patterned apertures and a second pattern in a second layer maycomprise a printed pattern or a patterned adhesive. As another example,a first pattern in a first layer may comprise lower opacity zonespositioned within a higher opacity zone and a second pattern in a secondlayer may comprise a printed pattern or a patterned adhesive. As stillanother example, a first pattern in a first layer may comprise loweropacity zones positioned within a higher opacity zone, apertures, orpatterned apertures and a second pattern in a second layer may compriseapertures, patterned apertures, and/or a pattern of embossments. Thefirst layer may be the layer facing the viewer, but the second layercould be as well.

As referenced above, the color of the layers in a moiré effect laminatemay be the same or different. As an example, a first layer may be whiteand a second layer may be blue. As another example, a first layer may belight blue and a second layer may be dark blue. Any of the layers may bethe same or a different color as the patterns of printed ink orpatterned adhesive.

In an instance, a first layer of a moiré effect laminate may comprise agarment-facing nonwoven layer and a second layer may comprise abacksheet film or other film. The garment-facing nonwoven layer may haveapertures, patterned apertures (as described herein), or lower opacityzones within a higher opacity zone. These apertures, patternedapertures, or lower opacity zones may form the first pattern in thefirst layer. The first layer may comprise one or more substrates as alaminate. The second layer comprising the backsheet film or other filmmay comprise a second pattern comprising apertures, patterned apertures,printed inks, patterned adhesives, and/or patterns of embossments. Thesecond pattern may be at least partially visible through the firstpattern in the first layer.

The first layer of the moiré effect laminate may be intermittentlyjoined or bonded to the second layer of the moiré effect laminate (oradditional layers) using any suitable type of joining or bonding.Examples of suitable joining or bonding include ultrasonic bonding orjoining, adhesive bonding or joining, mechanically bonding or joining,interpenetration of one layer into another layer, mechanicalentanglement, and/or thermal joining or bonding, for example. The bondsor joined portions may be placed at least about 15 mm, at least about 20mm, at least about 25 m, at least about 30 mm, at least about 35 mm, atleast about 40 mm, at least about 45 mm, or at least about 50 mm apart.In other instances, the bonds or joined portions may be positioned inthe range of about 15 mm to about 150 mm apart, about 20 mm to about 140mm apart, about 20 mm to about 120 mm apart, about 30 mm to about 100 mmapart, specifically reciting all 0.1 mm increments within theabove-referenced ranges and all ranges formed therein or thereby. Inlarger products, the bonds or joined portions may be positioned in therange of about 25 mm to about 1000 mm apart, about 100 mm to about 750mm apart, or about 100 mm to about 500 mm apart, specifically recitingall 0.1 mm increments within the above-referenced ranges and all rangesformed therein or thereby.

Referring to FIGS. 88-90, example bonds or joined portions 1108 areillustrated in simplistic views for ease in understanding. The bonds orjoined portions 1108 may be between the first and second layers (oradditional layers) of a moiré effect laminate. In FIGS. 88-90, anexample absorbent article 1110 is illustrated with a garment-facingsurface (or first layer) removed to show the locations of the bonds orjoined portions, although the bonding or joining concept applies to anymoiré effect laminate, regardless of where used in an absorbent articleor another consumer product. For example, the moiré effect laminatescould be used as topsheets, topsheets and acquisition layers, topsheetsand distribution layers, waist bands, outer covers, leg cuffs, belts,fastening systems, wipes, or as any other component of consumer productsor absorbent articles that have natural movement when in use (e.g.,ears). The bonds or joined portions 1108 may be discrete (see FIG. 88),linear and continuous (see FIGS. 89 and 90), discontinuous and linear,or discontinuous, for example. In various instances, the bonds or joinedportions may form any suitable or desired patterns.

In view of the bond or joined portion spacing described above, againreferring to FIGS. 88-90, non-joined spans 1112 may exist intermediatethe bonds or joined portions 1108 in a moiré effect laminate. Thesenon-joined spans 1112 are areas where the first layer is not joined orbonded to the second layer (or an additional layer, if provided in amoiré effect laminate). They can also be referred to as non-bondedspans. The non-bonded spans may extend in any suitable direction betweenthe bonds or joined portions. The first and second layers within thenon-joined spans 1112 may be moveable relative to each other, even ifjust slightly to allow for the moiré effect. The non-joined spans mayhave distances in the range of at least about 15 mm, at least about 20mm, at least about 25 mm, at least about 30 mm, at least about 35 mm, atleast about 40 mm, at least about 45 mm, or at least about 50 mm, forexample. In other instances, the non-joined spans may be positioned inthe range of about 15 mm to about 150 mm apart, about 20 mm to about 140mm apart, about 20 mm to about 120 mm apart, about 30 mm to about 100 mmapart, specifically reciting all 0.1 mm increments within theabove-referenced ranges and all ranges formed therein or thereby. Inlarger products, the non-joined spans may be positioned in the range ofabout 25 mm to about 1000 mm apart, about 100 mm to about 750 mm apart,or about 100 mm to about 500 mm apart, specifically reciting all 0.1 mmincrements within the above-referenced ranges and all ranges formedtherein or thereby.

In some instances, a path length in a non-joined or non-bonded span maybe greater, less, the same, or different in one of the layers of a moiréeffect laminate relative to another one of the layers. Referring to FIG.91, a first layer 1100 may have a greater path length, P1, than a pathlength P2, of the second layer 1102 in a non-joined span 1112. Pathlength is the distance traveled when moving over a surface from one bondor joined portion 1108 to another. As can be seen, the distance traveledwould be greater for the first layer 1100 than the second layer 1102.Stated another way, the first layer 1100 is longer than the second layer1102 in the non-joined span. The opposite may also be true with the pathlength of the second layer 1102 being greater than the first layer 1100.Providing a laminate with two layers, where the two layers havedifferent path lengths may be provided by pre-straining one layer beforejoining it to another non-pre-strained layer, as described in greaterdetail herein. By providing this path length differential, a moiréeffect laminate may provide three dimensional features in at least onelayer, while also increasing the visual significance of the moiré effectas one layer is allowed to move more relative to another layer withinthe non-joined or non-bonded span 1112. In the example of FIG. 91, thefirst layer 1100 may have apertures, patterned apertures, or loweropacity zones in a first pattern and the second layer 1102 may have aprinted pattern, a printed ink, a patterned adhesive, apertures, and/orpatterned apertures that are at least partially visible through theapertures, patterned apertures, or lower opacity zones in the firstlayer. The path length of a first layer may be at least about 0.5%,about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 4%, about5%, about 6%, about 7%, about 8%, about 9%, about 10%, or in the rangeof about 0.5% to about 40% greater than or different than the pathlength of a second layer in a moiré effect laminate, specificallyreciting all 0.1% increments with the specified range and all rangesformed therein.

Even without a different path length between the layers in thenon-joined spans, the first and second layers within the non-joined spanmay still be able to move relative to each other. This allows the moiréeffect to be observed. Movement between the first and second layers inthe non-bonded span or span may be caused by movement of a wearer of anabsorbent article and/or movement of the consumer product that the moirélaminate is part of.

FIG. 92 illustrates an example of a first layer 1100 of a moiré effectlaminate having a first pattern 1004. The first pattern may compriseapertures, patterned apertures, or lower opacity zones positioned withina higher opacity zone. FIG. 93 illustrates an example of a second layer1102 of a moiré effect laminate having a second pattern 1106. The secondpattern 1106 may comprise apertures, patterned apertures, printed inks,patterned adhesives, and/or embossments, for example. FIG. 94illustrates the first layer 1100 in a first position relative to thesecond layer 1102 in a non-joined span. FIG. 95 illustrates the firstlayer 1100 in a second position relative to the second layer 1102 in thesame non-joined span. As can be seen, a first portion of the secondpattern 1106 is visible through the first pattern 1104 when the firstlayer 1100 is in the first position and a second portion of the secondpattern 1106 is visible through the first pattern 1104 when the firstlayer 1102 is in the second position. The first pattern 1104 and thesecond pattern 1106 may be the same size and shape.

FIG. 96 illustrates an example of another first layer 1100 of a moiréeffect laminate having a first pattern 1104. The first pattern maycomprise apertures, patterned apertures, or lower opacity zonespositioned within a higher opacity zone. FIG. 97 illustrates an exampleof a second layer 1102 of a moiré effect laminate having a secondpattern 1106. The second pattern 1106 may comprise apertures, patternedapertures, printed inks, patterned adhesives, and/or embossments, forexample. FIG. 98 illustrates the first layer 1100 in a first positionrelative to the second layer 1102 in a non-joined span. FIG. 99illustrates the first layer 1100 in a second position relative to thesecond layer 1102 in the same non-joined span. As can be seen, a firstportion of the second pattern 1106 is visible through the first pattern1104 when the first layer 1100 is in the first position and a secondportion of the second pattern 1106 is visible through the first pattern1104 when the first layer 1102 is in the second position. The firstpattern 1104 and the second pattern 1106 may be a different size andshape.

FIG. 100 illustrates a cross-sectional illustration of a portion of anon-joined span of a moiré effect laminate, wherein the first layer 1100is in a first position relative to the second layer 1102, and wherein afirst portion of the second pattern 1106 is visible through the firstpattern 1104. In such an example, the first pattern 1104 is a pluralityof apertures or patterned apertures and the second pattern 1106 is aplurality of apertures or patterned apertures.

FIG. 101 illustrates another cross-sectional illustration of the portionof the non-joined span of the moiré effect laminate of FIG. 100, whereinthe first layer 1100 has been moved into a second position relative tothe second layer 1102, and wherein a second portion of the secondpattern 1106 is visible through the first pattern 1004.

FIG. 102 illustrates a cross-sectional illustration of a portion of anon-joined span of a moiré effect laminate, wherein the first layer 1100is in a first position relative to the second layer 1102, and wherein afirst portion of the second pattern 1106 is visible through the firstpattern 1104. In such an example, the first pattern 1104 is a pluralityof lower opacity zones in a higher opacity zone and the second pattern1106 is a plurality of apertures or patterned apertures.

FIG. 103 illustrates another cross-sectional illustration of the portionof the non-joined span of the moiré effect laminate of FIG. 101, whereinthe first layer 1100 has been moved into a second position relative tothe second layer 1102, and wherein a second portion of the secondpattern 1106 is visible through the first pattern 1004.

Any of the moiré effect laminates disclosed herein may have a patternformed by patterned apertures having any parameters of the patternedapertures set forth herein, such as Interaperture Distance and AverageAbsolute Feret Angle, for example.

A method of producing moiré effect laminate is provided. The method maycomprise providing a first layer, a first nonwoven layer, or a firstfilm layer, comprising a plurality of lower opacity zones positionedwithin a higher opacity zone (opacity differences are discussed above).The lower opacity zones may comprise or be apertures. The plurality oflower opacity zones may form a first pattern. The method may compriseproviding a second layer, a second nonwoven layer, or a second filmlayer, comprising a second pattern and positioning the first layer in aface-to-face relationship with the second layer. The method may compriseintermittently joining the first layer to the second layer to form atleast one non-joined span of the first and second layers such that atleast a portion of the first layer is moveable relative to a portion ofthe second layer within the non-joined span. The non-joined span mayhave a dimension of at least 20 mm (or any of the dimensions set forthabove for the non-joined or non-bonded spans). Portions of the secondpattern may be aligned, or partially aligned, with portions of the firstpattern in the non-joined span. A portion of the second pattern and aportion of the first pattern may be present in the non-joined span. Thefirst pattern may be the same or different than the second pattern insize, shape, and/or orientation, for example. A first path length in thefirst layer of the non-joined span may be different than, greater than,or less than a second path length in the second layer of the non-joinedspan by any of the percentages disclosed above.

A method of producing an optical interference pattern in an absorbentarticle is provided. The method may comprise providing a first layer(nonwoven or film) as a first component of the absorbent article. Thefirst layer may comprise a plurality of lower opacity zones positionedwithin a higher opacity zone (differences in opacity are describedabove). The plurality of lower opacity zones may form a first pattern.The lower opacity zones may comprise apertures. The method may compriseproviding a second layer (nonwoven or film) as a second component of theabsorbent article. The second layer may comprise a second pattern. Thefirst layer, or a portion thereof, may be in a face-to-face relationshipwith the second layer, or a portion thereof, and is intermittentlyjoined to the second layer to thereby form at least one non-joined span.The method may comprise allowing a portion of the first layer, in thenon-joined span, to move relative to a portion of the second layer, inthe non-joined span, to produce the optical interference pattern. Afirst portion of the second pattern, in the non-joined span, may bevisible through a portion of the first pattern, in the non-joined span,when the portion of the first layer is in a first position relative tothe portion of the second layer. A second portion of the second pattern,in the non-joined span, may be visible through the portion of the firstpattern, in the non-joined span, when the portion of the first layer isin a second position relative to the portion of the second layer. Thefirst component of the absorbent article may be a topsheet, anacquisition layer, or any other suitable component. The second componentof the absorbent article may be a secondary topsheet, an acquisitionlayer, a backsheet, or any other suitable component.

Zonal Patterned Apertured Webs

Referring to FIGS. 104-107, aspects of zonal patterned apertured websare illustrated. The various zones are represented as Z1, Z2, etc. tosignify zone 1, zone 2 etc. Although the zonal patterned apertured webare illustrated as either a garment-facing layer or laminate orwearer-facing layer or laminate in FIGS. 104-107, it will be understoodthat zonal patterned apertured web, whether comprising one layer ormultiple layers, may also be used for any portion of an absorbentarticle or other consumer product. For example, a zonal patternedapertured web may be used as part of an ear panel, a wipe, and/or abarrier leg cuff. The zonal patterned apertured webs may have one ormore layers that is pre-strained and joined to non-pre-strained layers,as described herein.

Referring to FIG. 104, a first zone, Z1, represents a front portion ofan absorbent article while a second zone, Z2, represents a rear portionof an absorbent article. The first and second zones are formed in apatterned apertured web that may be a single layer or multiple layers.The patterned apertured web 1300 may comprise a plurality of firstarrays forming the first zone, Z1. At least some of the first arrays maycomprise a first plurality of land areas and a first plurality ofapertures. At least some of the first plurality of land areas surroundat least some of the first plurality of apertures. The first zone, Z1,may have a plurality of Interaperture Distances, according to theAperture Test herein. The Interaperture Distances of the first zone, Z1,may have a first distribution having a first mean and a first median.The first mean may be greater than, less than, or different than thefirst median by at least 4% or other percentage, such as 8%, forexample. The first arrays in the first zone, Z1, may have an EffectiveOpen Area, according to the Aperture Test herein, in the range of about5% to about 50%, also including any other ranges specified herein. Anexample of first arrays that may form the first zone, Z1, is illustratedin FIG. 1, along with land areas 14 and apertures 12. Any of the otherpatterned apertured webs of the present disclosure may also form all ofor part of the first zone, Z1.

A plurality of second, different arrays may form the second zone, Z2, inthe patterned apertured web 1300. At least some of the second arrays maycomprise a second plurality of land areas and a second plurality ofapertures. At least some of the second land areas may surround at leastsome of the second plurality of apertures. The second zone, Z2, may havea plurality of Interaperture Distances, according to the Aperture Testherein. The Interaperture Distances of the second zone, Z2, may have asecond distribution having a second mean and a second median. The secondmean may be greater than, less than, or different than the second medianby at least 4% or other percentage, such as 8%, for example. The secondarrays in the second zone, Z2, may have an Effective Open Area,according to the Aperture Test herein, of about 5% to about 50%, alsoincluding any other ranges specified herein. An example of second arraysthat may form the second zone, Z2, is illustrated in FIG. 2, along withland areas 14 and apertures 12. Any of the other patterned aperturedwebs of the present disclosure may also form all of or part of thesecond zone, Z2.

The patterned apertured web in either of the zones, Z1 or Z2, maycomprise one or more layers or may only comprise a single layer. Thelayer or layers may comprise films, nonwoven material or any of theother materials specified herein. In a multi-layer patterned aperturedweb, the layers may comprise the same materials or different materials,with at least one of the layers having patterned apertures. The layersmay have the same or different colors. The first plurality of aperturesin the first zone, Z1, may be the same as or different than theplurality of apertures in the second zone, Z2. The first plurality ofapertures in the first array or the second plurality of apertures in thesecond array may form a substantially continuous pattern, a discretepattern, or a linear pattern. The first plurality of land areas in thefirst array or the second plurality of land area in the second array mayform a substantially continuous pattern, a discrete pattern, or a linearpattern.

The first zone, Z1, or the second zone, Z2, may indicate the correctorientation of the absorbent article on a wearer. The patternedapertured web 1300 may comprise a polyethylene/polypropylene bicomponentspunbond material, nanofibers, and/or crimped fibers.

A patterned apertured web (single or multi-layer) may comprise aplurality of first arrays forming a first zone, Z1, in the patternedapertured web 1300. At least some of the first arrays may comprise afirst plurality of land areas and a first plurality of non-homogeneousapertures. At least some of the first plurality of land areas maysurround at least some of the first plurality of apertures. The firstplurality of apertures may have an Average Absolute Feret Angle ofgreater than about 20 degrees (or other degrees as set forth herein),according to the Aperture Test herein. The first arrays may have anEffective Open Area, according to the Aperture Test herein, in the rangeof about 5% to about 50% (or other percentages or ranges specifiedherein). A plurality of second, different arrays may form a second zone,Z2, in the patterned aperture web. At least some of the second arraysmay comprise second plurality of land areas and a second plurality ofnon-homogeneous apertures, wherein at least some of the second pluralityof land areas surround at least some of the second plurality ofapertures. The second arrays may have an Effective Open Area, accordingto the Aperture Test, of about 5% to about 50% (or other percentages orranges specified herein). The second plurality of apertures may alsohave an Average Absolute Feret Angle of greater than about 20 degrees,according to the Aperture Test herein.

A patterned apertured web (whether single or multi-layer) may comprise aplurality of first arrays forming a first zone, Z1, in the patternedapertured web. At least some of the first arrays may comprise a firstplurality of land areas having a width greater than at least 5 mm, atleast 8 mm, or at least 10 mm and a first plurality of apertures. Atleast some of the first plurality of land areas may surround at leastsome of the first plurality of apertures. The first zone, Z1, may have aplurality of Interaperture Distances, according to the Aperture Testherein, wherein the Interaperture Distance of the first zone, Z1, mayhave a first distribution having a first mean and a first median. Thefirst mean may be greater than, less than, or different than the firstmedian by at least 4% or at least 8%. The first arrays may have anEffective Open Area, according to the Aperture Test, in the range ofabout 5% to about 50% (or other percentages or ranges specified herein).A plurality of second arrays may form second zone, Z2, in the patternedapertured web 1300. At least some of the second arrays may comprise asecond plurality of land areas having a width greater than at least 5mm, at least 8 mm, or at least 10 mm and a second plurality ofapertures. At least some of the second plurality of land areas maysurround at least some of the second plurality of apertures. The secondzone, Z2, may have a plurality of Interaperture Distances, according tothe Aperture Test herein. The Interaperture Distances of the secondzone, Z2, may have a second distribution having a second mean and asecond median. The second mean may be greater than, less than, ordifferent than the second median by at least 4% or at least 8% or in therange of about 4% to about 25%. The second arrays may have an EffectiveOpen Area in the range of about 5% to about 50% (or other percentages orranges specified herein).

A patterned apertured web may comprise a layer comprising a plurality ofapertures and a plurality of land areas. The plurality of apertures maycomprise a first set of apertures and a second set of apertures. Thefirst set of apertures may have Interaperture Distances, according tothe Aperture Test herein. The Interaperture Distances of the first setof apertures may have a first distribution having a first mean and afirst median. The first mean may be greater than, less than or differentthan, the first median. The second set of apertures may haveInteraperture Distances, according to the Aperture Test herein. TheInteraperture Distances of the second set of apertures may have a seconddistribution having a second mean and a second median. The second meanmay be greater than, less than, or different than the second median. Thefirst and second sets of apertures may have different patterns. Thepatterned apertured web 1300 may comprise a third set of apertures. Thethird set of apertures may be different than the first and second setsof apertures. The third set of apertures may have InterapertureDistances, according to the Aperture Test herein. The e InterapertureDistances of the third set of apertures may have a third distributionhaving a third mean and a third median. The third mean may be greaterthan, less than or different than the third median. The patternedapertured web 1300 may have one or more layers. One or more of thelayers may be apertured. In other instances, one or more of the layermay not be apertured. A first layer of the patterned apertured web maybe apertured and a second layer of the patterned apertured web may notbe apertured. In other instances, a first layer of a patterned aperturedweb may be apertured and a second layer of the patterned apertured webmay be apertured. The layers may have a different in hydrophilicity asdescribed herein. A portion of, or all of, the first layer or a portionof, or all of, the second layer may comprise apolyethylene/polypropylene bicomponent spunbond material, nanofibers,and/or crimped fibers.

Referring to FIG. 105, a patterned apertured web 1301 may have a firstzone, Z1, and a second zone, Z2. The first and second zones, Z1 and Z2,may have any of the features described above with respect to thepatterned apertured web 1300 and FIG. 104. The same applies to thepatterned apertured web 1302 of FIG. 106. In FIG. 106, the first zone,Z1, may be a first patterned apertured web, and the second zone, Z2, maybe a second patterned apertured web. The first patterned apertured webmay surround the second patterned apertured web or the second patternedapertured web may be a patch placed on or joined to the first patternedapertured web.

Referring to FIG. 107, a patterned apertured web 1303 may have a firstzone, Z1, a second zone, Z2, a third zone, Z3, and a fourth zone, Z4.The first, second, third, and fourth zones, Z1-Z4, may have any of thefeatures described above with respect to the patterned apertured web1300 and FIG. 104.

At least some of the zones of FIGS. 104-107 may not have patternedapertures or apertures in some instances.

Packages

The absorbent articles of the present disclosure may be placed intopackages. The packages may comprise polymeric films and/or othermaterials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate amount of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages.

Accordingly, packages of the absorbent articles of the presentdisclosure may have an In-Bag Stack Height of less than about 110 mm,less than about 105 mm, less than about 100 mm, less than about 95 mm,less than about 90 mm, less than about 85 mm, less than about 80 mm,less than about 78 mm, less than about 76 mm, less than about 74 mm,less than about 72 mm, or less than about 70 mm, specifically recitingall 0.1 mm increments within the specified ranges and all ranges formedtherein or thereby, according to the In-Bag Stack Height Test describedherein. Alternatively, packages of the absorbent articles of the presentdisclosure may have an In-Bag Stack Height of from about 70 mm to about110 mm, from about 70 mm to about 105 mm, from about 70 mm to about 100mm, from about 70 mm to about 95 mm, from about 70 mm to about 90 mm,from about 70 mm to about 85 mm, from about 72 mm to about 80 mm, orfrom about 74 mm to about 78 mm, specifically reciting all 0.1 mmincrements within the specified ranges and all ranges formed therein orthereby, according to the In-Back Stack Height Test described herein.

FIG. 108 illustrates an example package 1000 comprising a plurality ofabsorbent articles 1004. The package 1000 defines an interior space 1002in which the plurality of absorbent articles 1004 are situated. Theplurality of absorbent articles 1004 are arranged in one or more stacks1006.

Materials/Laminates Comprising Overbonds

Materials and/or laminates comprising overbonds are also within thescope of the present disclosure. The materials may be singleself-sustaining webs, while the laminates may be one or more singleself-sustaining webs that are joined together. In a laminate context,only one layer may comprise overbonds or all layers may compriseoverbonds. If overbonds are provided in more than one layer of alaminate, they may have the same patterns or different patterns. Any ofthe layers of the laminate may be pre-strained. The webs may be films,nonwovens, any other suitable materials, and/or any other materialsdescribed herein. The overbonds may be arranged in any suitablepatterns, such as the patterns of FIGS. 19-23, 31, 53, and 55-60, forexample. The overbonds may be applied at a nonwoven supplier or nonwovenmanufacture (without performing the cross-machine directional stretchingstep(s)) or may be applied at a site where the cross-machine directionalstretching step(s) is/are also conducted. Examples of the cross-machinedirection stretching steps are described herein with references to FIGS.16 and 24-30. The overbonded materials and/or laminates may be used toproduce the patterned apertured webs of the present disclosure.

Test Methods

Basis Weight Test

Basis weight of the patterned apertured webs may be determined byseveral available techniques, but a simple representative techniqueinvolves taking an absorbent article or other consumer product, removingany elastic which may be present and stretching the absorbent article orother consumer product to its full length. A punch die having an area of45.6 cm² is then used to cut a piece of the patterned apertured web(e.g., topsheet, outer cover) from the approximate center of theabsorbent article or other consumer product in a location which avoidsto the greatest extent possible any adhesive which may be used to fastenthe patterned apertured web to any other layers which may be present andremoving the patterned apertured web from other layers (using cryogenicspray, such as Cyto-Freeze, Control Company, Houston, Tex., if needed).The sample is then weighed and dividing by the area of the punch dieyields the basis weight of the patterned apertured web. Results arereported as a mean of 5 samples to the nearest 0.1 cm².

Aperture Test

Aperture dimensions, Effective Aperture Area, % Effective Open Area,Interaperture Distance measurements, among other measurements, areobtained from specimen images acquired using a flatbed scanner. Thescanner is capable of scanning in reflectance mode at a resolution of6400 dpi and 8 bit grayscale (a suitable scanner is an Epson PerfectionV750 Pro from Epson America Inc., Long Beach Calif. or equivalent). Thescanner is interfaced with a computer running an image analysis program(a suitable program is ImageJ v. 1.47 or equivalent, National Instituteof Health, USA). The specimen images are distance calibrated against anacquired image of a ruler certified by NIST. A steel frame is used tomount the specimen, which is then backed with a black glass tile (P/N11-0050-30, available from HunterLab, Reston, Va.) prior to acquiringthe specimen image. The resulting image is then thresheld, separatingopen aperture regions from specimen material regions, and analyzed usingthe image analysis program. All testing is performed in a conditionedroom maintained at about 23±2° C. and about 50±2% relative humidity.

Sample Preparation:

To obtain a specimen, tape an absorbent article to a rigid flat surfacein a planar configuration. Any leg elastics may be cut to facilitatelaying the article flat. A rectilinear steel frame (100 mm square, 1.5mm thick with an opening 60 mm square) is used to mount the specimen.Take the steel frame and place double-sided adhesive tape on the bottomsurface surrounding the interior opening. Remove the release paper ofthe tape, and adhere the steel frame to the apertured layer of thearticle. Align the frame so that it is parallel and perpendicular to amachine direction (MD) and a cross direction (CD) of the aperturedlayer. Using a razor blade excise the apertured layer from theunderlying layers of the article around the outer perimeter of theframe. Carefully remove the specimen such that its longitudinal andlateral extension is maintained to avoid distortion of the apertures. Acryogenic spray (such as Cyto-Freeze, Control Company, Houston Tex.) maybe used to remove the specimen from the underlying layers if necessary.Five replicates obtained from five substantially similar articles areprepared for analysis. If the apertured layer of interest is too smallto accommodate the steel frame, reduce the frame dimensions accordinglyto accomplish the goals of removal of the specimen without distortion ofthe apertures while leaving an opening of sufficient size to allow forscanning a significant portion of the apertured layer. An apertured orpatterned apertured substrate raw material is prepared for testing byextending or activating it under the same process conditions, and to thesame extent, as it would be for use on the absorbent article, and thenin its extended state adhering it to the steel frame as described abovefor testing. Condition the samples at about 23° C.±2 C.° and about50%±2% relative humidity for 2 hours prior to testing.

Image Acquisition:

Place the ruler on the scanner bed, oriented parallel to sides of thescanner glass, and close the lid. Acquire a calibration image of theruler in reflectance mode at a resolution of 6400 dpi (approximately 252pixels per mm) and 8 bit grayscale, with the field of view correspondingto the dimensions of an interior of the steel frame. Save thecalibration image as an uncompressed TIFF format file. Lift the lid andremove the ruler. After obtaining the calibration image, all specimensare scanned under the same conditions and measured based on the samecalibration file. Next, place the framed specimen onto the center of thescanner bed, lying flat, with the outward facing surface of the specimenfacing the scanner's glass surface. Orient the specimen so that sides ofthe frame are aligned parallel with and perpendicular to the sides ofthe scanner's glass surface, so that the resulting specimen image willhave the MD vertically running from top to bottom. Place the black glasstile on top of the frame covering the specimen, close the lid andacquire a scanned image. Scan the remaining four replicates in likefashion. If necessary, crop all images to a rectangular field of viewcircumscribing the apertured region, and resave the files.

% Effective Open Area Calculation:

Open the calibration image file in the image analysis program andperform a linear distance calibration using the imaged ruler. Thisdistance calibration scale will be applied to all subsequent specimenimages prior to analysis. Open a specimen image in the image analysisprogram and set the distance scale. View the 8 bit histogram (0 to 255,with one bin per GL) and identify the gray level (GL) value for theminimum population located between the dark pixel peak of the apertureholes and the lighter pixel peak of the specimen material. Threshold theimage at the minimum gray level value to generate a binary image. In thebinary image the apertures appear as black, with a GL value of 255, andspecimen as white, with a GL value of 0.

Using the image analysis program, analyze each of the discrete apertureregions. Measure and record all of the individual aperture areas to thenearest 0.01 mm², including partial apertures along the edges of theimage. Discard any apertures with an area less than 0.3 mm² as“non-effective”. Sum the remaining aperture areas (including whole andpartial apertures), divide by the total area included in the image andmultiply by 100. Record this value as the % effective open area to thenearest 0.01%.

In like fashion, analyze the remaining four specimen images. Calculateand report the average % effective open area values to the nearest 0.01%for the five replicates.

Effective Aperture Dimension Measurements:

Open the calibration image (containing the ruler) file in the imageanalysis program. Resize the resolution of the original image from 6400dpi to 640 dpi (approximately 25.2 pixels per mm) using a bicubicinterpolation. Perform a linear distance calibration using the imagedruler. This distance calibration scale will be applied to all subsequentspecimen images prior to analysis. Open a specimen image in the imageanalysis program. Resize the resolution of the original image from 6400dpi to 640 dpi (approximately 25.2 pixels per mm) using a bicubicinterpolation. Set the distance scale. View the 8 bit histogram (0 to255, with one bin per GL) and identify the gray level (GL) value for theminimum population located between the dark pixel peak of the apertureholes and the lighter pixel peak of the specimen material. Threshold theimage at the minimum gray level value to generate a binary image. In thebinary image, the apertures appear as black, with a GL value of 255, andspecimen as white, with a GL value of 0. Next, two morphologicaloperations are performed on the binary image. First, a closing (adilation operation followed by an erosion operation, iterations=1, pixelcount=1), which removes stray fibers within an aperture hole. Second, anopening (an erosion operation followed by a dilation operation,iterations=1, pixel count=1), which removes isolated black pixels. Padthe edges of the image during the erosion step to ensure that blackboundary pixels are maintained during the operation. Lastly, fill anyremaining voids enclosed within the black aperture regions.

Using the image analysis program, analyze each of the discrete apertureregions. During the analysis exclude measurements of partial aperturesalong the edges of the image, so that only whole apertures are measured.Measure and record all of the individual effective aperture areas,perimeters, feret diameters (length of the apertures) along with itscorresponding angle of orientation in degrees from 0 to 180, and minimumferet diameters (width of the apertures). Record the measurements foreach of the individual elements areas to the nearest 0.01 mm², theperimeters and feret diameters (length and width), to the nearest 0.01mm, and angles to the nearest 0.01 degree. Discard any apertures with anarea less than 0.3 mm² as “non-effective”. Record the number ofremaining apertures, divide by the area of the image and record as theAperture Density value. The angle of orientation for an aperture alignedwith the MD (vertical in the image) will have an angle of 90 degrees.Apertures with a positive slope, increasing from left to right, willhave an angle between zero and 90 degrees. Apertures with a negativeslope, decreasing from left to right, will have an angle between 90 and180 degrees. Using the individual aperture angles calculate an AbsoluteFeret Angle by subtracting 90 degrees from the original angle oforientation and taking its absolute value. In addition to thesemeasurements, calculate an Aspect Ratio value for each individualaperture by dividing the aperture length by its width. Repeat thisanalysis for each of the remaining four replicate images. Calculate andreport the statistical mean and standard deviation for each of theeffective aperture dimension, the Absolute Feret Angle, and the AspectRatio measurements using all of the aperture values recorded from thereplicates. Record the average of the individual Absolute Feret Anglemeasurements as the Average Absolute Feret Angle value. Calculate andreport the % relative standard deviation (RSD) for each of the aperturedimension, the Absolute Feret Angle, and the Aspect Ratio measurementsby dividing the standard deviation by the mean and multiplying by 100.

Inter-Aperture Distance Measurements:

The mean, standard deviation, median, and maximum distance between theapertures can be measured by further analyzing the binary image that wasanalyzed for the aperture dimension measurements. First, obtain aduplicate copy of the resized binary image following the morphologicaloperations, and using the image analysis program, perform a Voronoioperation. This generates an image of cells bounded by lines of pixelshaving equal distance to the borders of the two nearest patternapertures, where the pixel values are outputs from a Euclidian distancemap (EDM) of the binary image. An EDM is generated when eachinteraperture pixel in the binary image is replaced with a value equalto that pixel's distance from the nearest pattern aperture. Next, removethe background zeros to enable statistical analysis of the distancevalues. This is accomplished by using the image calculator to divide theVoronoi cell image by itself to generate a 32-bit floating point imagewhere all of the cell lines have a value of one, and the remaining partsof the image are identified as Not a Number (NaN). Lastly, using theimage calculator, multiply this image by the original Voronoi cell imageto generate a 32-bit floating point image where the distance valuesalong the cell lines remain, and all of the zero values have beenreplaced with NaN. Next, convert the pixel distance values into actualinter-aperture distances by multiplying the values in the image by thepixel resolution of the image (approximately 0.04 mm per pixel), andthen multiply the image again by 2 since the values represent themidpoint distance between apertures. Measure and record the mean,standard deviation, median and maximum inter-aperture distances for theimage to the nearest 0.01 mm. Repeat this procedure for all replicateimages. Calculate the % relative standard deviation (RSD) for theinteraperture distance by dividing the standard deviation by the meanand multiplying by 100.

Opacity Test

Opacity by contrast ratio measurements are made using a 0°/45°spectrophotometer suitable for making standard CIE L*a*b* colormeasurements (e.g., Hunterlab Labscan XE spectrophotometer, HunterAssociates Laboratory Inc., Reston Va. or equivalent). The diameter ofthe instrument's measurement port should be chosen such that only theregion of interest is included within the measurement port. Analyses areperformed in a room controlled at about 23° C.±2 C.° and 50%±2% relativehumidity. Samples are conditioned at the same condition for 2 hoursbefore testing.

Calibrate the instrument per the vender instructions using the standardblack and white tiles provided by the vendor. Set the spectrophotometerto use the CIE XYZ color space, with a D65 standard illumination and 10°observer. If the specimen is a layer of an article, use cryogenic sprayand scissors to carefully excise the specimen from the article fortesting, otherwise obtain the specimen from a representative sample ofmaterial of sufficient size for testing. Place the specimen flat againstthe instrument with the outward facing surface toward thespectrophotometer's measurement port and the region of interest withinthe port. Ensure that no tears, holes or apertures are within themeasurement port. Place the white standard tile onto the opposingsurface of the specimen such that it completely covers the measurementport. Take a reading for XYZ and record to 0.01 units. Without movingthe specimen, remove the white plate and replace it with the blackstandard plate. Take a second reading for XYZ and record to 0.01 units.Repeat this procedure at a corresponding site for a total of ten (10)replicate specimens.

Opacity is calculated by dividing the Y value measured using the blacktile as backing, divided by the Y value measured using the white tile asbacking, then multiplying the ratio by 100. Record the opacity value tothe nearest 0.01%. Calculate opacity for the 10 replicates and reportthe average opacity to the nearest 0.01%.

Light Transmission Test

The light transmission test measures the average amount of lighttransmitted through specific regions of a specimen. A calibrated lighttransmission image is obtained using a flatbed scanner. A binary mask isgenerated to separate discrete aperture regions from the surroundingland area. The binary mask is then registered to the light transmissionimage, and used to exclude the apertures from the land area in the lighttransmission image. This enables the average light transmission valuefor the land area to be calculated.

Sample Preparation:

To obtain a specimen, tape the absorbent article to a rigid flat surfacein a planar configuration. Any leg elastics may be cut to facilitatelaying the article flat. A rectilinear steel frame (100 mm square, 1.5mm thick with an opening 60 mm square) is used to mount the specimen.Take the steel frame and place double-sided adhesive tape on the bottomsurface surrounding the interior opening. Remove the release paper ofthe tape, and adhere the steel frame to the apertured layer of thearticle. Align the frame so that it is parallel and perpendicular to themachine direction (MD) and cross direction (CD) of the apertured layer.Using a razor blade excise the apertured layer from the underlyinglayers of the article around the outer perimeter of the frame. Carefullyremove the specimen such that its longitudinal and lateral extension ismaintained to avoid distortion of the apertures. A cryogenic spray (suchas Cyto-Freeze, Control Company, Houston Tex.) can be used to remove thespecimen from the underlying layers if necessary. Five replicatesobtained from five substantially similar articles are prepared foranalysis. If the aperture layer of interest is too small to accommodatethe steel frame, reduce the frame dimensions accordingly to accomplishthe goals of removal of the specimen without distortion of the apertureswhile leaving an opening of sufficient size to allow for scanning asignificant portion of the apertured layer. An apertured substrate rawmaterial is prepared for testing by extending or activating it under thesame process conditions, and to the same extent, as it would be for useon the absorbent article, and then in its extended state adhering it tothe steel frame as described above for testing. Condition the samples atabout 23° C.±2 C.° and about 50%±2% relative humidity for 2 hours priorto testing.

Light Transmission Image

The light transmission measurement is based on the CIE L*a*b* colorsystem (CIELAB). A flatbed scanner capable of scanning a minimum of 24bit color at 800 dpi and has manual control of color management (asuitable scanner is an Epson Perfection V750 Pro from Epson AmericaInc., Long Beach Calif. or equivalent) is used to acquire images. Thescanner is interfaced with a computer running color management software(suitable color management software is MonacoEZColor available fromX-Rite Grand Rapids, Mich. or equivalent). The scanner is calibratedagainst a color transparency target and corresponding reference filecompliant with ANSI method IT8.7/1-1993 using the color managementsoftware to construct a calibrated color profile. The resultingcalibrated scanner profile is used to color correct an image from a testspecimen within an image analysis program that supports sampling in CIEL*a*b* (a suitable program is Photoshop S4 available from Adobe SystemsInc., San Jose, Calif. or equivalent). All testing is performed in aconditioned room maintained at about 23±2° C. and about 50±2% relativehumidity.

Turn on the scanner for 30 minutes prior to calibration. Deselect anyautomatic color correction or color management options that may beincluded in the scanner software. If the automatic color managementcannot be disabled, the scanner is not appropriate for this application.Place the IT8 target face down onto the scanner glass, close the scannerlid, acquire an image at 200 dpi and 24 bit color and remove the IT8target. Open the image file on the computer with the color managementsoftware. Follow the recommended steps within the color managementsoftware to create and export a calibrated color profile. These stepsmay include, ensuring that the scanned image is oriented and croppedcorrectly. The calibrated color profile must be compatible with theimage analysis program. The color management software uses the acquiredimage to compare with the included reference file to create and exportthe calibrated color profile. After the profile is created the scanresolution (dpi) for test specimens can be changed, but all othersettings must be kept constant while imaging specimens.

Open the scanner lid and place the specimen flat against the scannerglass with the outward facing surface facing the glass. Acquire andimport a scan of the specimen region within the interior of the frameinto the image analysis software at 24 bit color and at 800 dpi intransparency mode. If necessary, crop image to a rectangular field ofview circumscribing the apertured region. Transparency mode illuminatesthe specimen from one side with the sensor capturing the image from theopposite side. Assign the calibrated color profile to the image andchange the color space mode to L*a*b* Color corresponding to the CIEL*a*b* standard. This produces a color corrected image for analysis.Save this color corrected image in an uncompressed format, such as aTIFF file.

Land Area Mask

The boundaries of the apertured areas and land area are identified bythresholding the L* channel image to generate a binary image, separatingapertured areas from the surrounding land area. This binary image willthen be used as a mask on the corresponding light transmission image tomeasure the average Light Transmission Value of only the land area.

To do this, first open the color corrected light transmission image inthe image analysis software. To generate the land area mask, firstseparate the L*, a* and b* channels, and select only the L* channel foranalysis. The L* channel represents the “Lightness” of the image and hasvalues that range from 0-100. Threshold the L* channel image at a valueof 90 to generate a binary image.

By thresholding at the level described above, a binary mask image isproduced with the discrete aperture areas assigned one value, and thesurrounding land area assigned a different value. For example, thediscrete aperture areas could appear black, and the surrounding landarea could appear white. Save this binary mask image in an uncompressedformat, such as a TIFF file.

Analysis of Light Transmission Image

Open both the color corrected light transmission image and thecorresponding binary mask image in the image analysis software. Toanalyze the specimen light transmission image, first separate the L*, a*and b* channels, and select only the L* channel for analysis. Registerthe light transmission image and the binary mask image to each other.Use the binary mask to exclude the apertures from the light transmissionimage, and calculate an average L* value (Light Transmission Value) forthe remaining surrounding land area. Record this value as the Land AreaLight Transmission Value to the nearest 0.1 units. In like fashion,repeat this procedure on all of the replicate specimens. Calculate andreport the average of the five individual Land Area Light TransmissionValues to the nearest 0.1 units.

In-Bag Stack Height Test

The in-bag stack height of a package of absorbent articles is determinedas follows:

Equipment

A thickness tester with a flat, rigid horizontal sliding plate is used.The thickness tester is configured so that the horizontal sliding platemoves freely in a vertical direction with the horizontal sliding platealways maintained in a horizontal orientation directly above a flat,rigid horizontal base plate. The thickness tester includes a suitabledevice for measuring the gap between the horizontal sliding plate andthe horizontal base plate to within ±0.5 mm. The horizontal slidingplate and the horizontal base plate are larger than the surface of theabsorbent article package that contacts each plate, i.e. each plateextends past the contact surface of the absorbent article package in alldirections. The horizontal sliding plate exerts a downward force of850±1 gram-force (8.34 N) on the absorbent article package, which may beachieved by placing a suitable weight on the center of thenon-package-contacting top surface of the horizontal sliding plate sothat the total mass of the sliding plate plus added weight is 850±1grams.

Test Procedure

Absorbent article packages are equilibrated at 23±2° C. and 50±5%relative humidity prior to measurement.

The horizontal sliding plate is raised and an absorbent article packageis placed centrally under the horizontal sliding plate in such a waythat the absorbent articles within the package are in a horizontalorientation (see FIG. 108). Any handle or other packaging feature on thesurfaces of the package that would contact either of the plates isfolded flat against the surface of the package so as to minimize theirimpact on the measurement. The horizontal sliding plate is loweredslowly until it contacts the top surface of the package and thenreleased. The gap between the horizontal plates is measured to within±0.5 mm ten seconds after releasing the horizontal sliding plate. Fiveidentical packages (same size packages and same absorbent articlescounts) are measured and the arithmetic mean is reported as the packagewidth. The “In-Bag Stack Height”=(package width/absorbent article countper stack)×10 is calculated and reported to within ±0.5 mm.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited herein, including any cross referenced or relatedpatent, patent publication, or patent application, is herebyincorporated by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests, or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular forms of the present disclosure have been illustratedand described, those of skill in the art will recognize that variousother changes and modifications can be made without departing from thespirit and scope of the invention. It is therefore intended to cover inthe appended claims all such changes and modifications that are withinthe scope of the present disclosure.

What is claimed is:
 1. A method of forming an outer cover and backsheet three-dimensional laminate for an absorbent article, the method comprising: providing a first nonwoven layer configured to be an outer cover in the absorbent article; providing a second film layer configured to be a backsheet in the absorbent article; wherein only the first nonwoven layer has a plurality of apertures defined therein; wherein the second film layer is free of apertures; applying a pre-strain force to only one of the first nonwoven layer or the second film layer; joining the first nonwoven layer to the second film layer while the first nonwoven layer or the second film layer is in a pre-strained condition; releasing the pre-strain force to allow the first nonwoven layer or the second film layer to at least partially recover and form the outer cover and backsheet three-dimensional laminate; and wherein the laminate is free of elastic strands.
 2. The method of claim 1, wherein at least some of the plurality of apertures are non-homogenous apertures.
 3. The method of claim 1, comprising: providing a third layer; and joining the third layer to the first nonwoven layer or to the second film layer.
 4. The method of claim 1, comprising: applying a pigmented patterned adhesive or an ink to the first nonwoven layer or to the second film layer.
 5. The method of claim 1, wherein the pre-strain force is applied substantially in a machine direction, and wherein the pre-strain force causes the first nonwoven layer or the second film layer to elongate by at least 5%.
 6. The method of claim 1, wherein the plurality of apertures have a plurality of Interaperture Distances, according to the Aperture Test herein, wherein the Interaperture Distances have a distribution having a median and a mean, and wherein the mean is different than the median.
 7. The method of claim 1, comprising only applying the pre-strain force to the first nonwoven layer.
 8. The method of claim 2, wherein the at least some of the plurality of apertures have an Aspect Ratio greater than
 2. 9. The method of claim 2, wherein the at least some of the plurality of apertures have an Average Absolute Feret Angle of at least 20 degrees.
 10. The method of claim 9, wherein the at least some of the plurality of apertures have melt-fused portions at least partially around perimeters of the apertures.
 11. A method of forming an outer cover and backsheet three-dimensional laminate for an absorbent article, the method comprising: providing a first nonwoven layer configured to be an outer cover of the absorbent article; providing a second film layer configured to be a backsheet of the absorbent article, wherein the second film layer is free of apertures, wherein only the first nonwoven layer has a plurality of apertures defined therein, and wherein at least some of the plurality of apertures are non-homogenous apertures; applying a pre-strain force to only one of the first nonwoven layer or the second film layer; joining the first nonwoven layer to the second film layer while the first nonwoven layer or the second film layer is in a pre-strained condition; and releasing the pre-strain force to allow the first nonwoven layer or the second film layer to at least partially recover and form the outer cover and backsheet three-dimensional laminate.
 12. The method of claim 11, wherein the at least some of the plurality of apertures have an Average Absolute Feret Angle of at least 20 degrees.
 13. The method of claim 12, wherein the at least some of the plurality of apertures have an Aspect Ratio greater than 2.5.
 14. The method of claim 13, wherein the at least some of the plurality of apertures have melt-fused portions at least partially around perimeters of the apertures.
 15. The method of claim 11, comprising only applying the pre-strain force to the first nonwoven layer.
 16. A method of forming an outer cover and backsheet three-dimensional laminate for an absorbent article, the method comprising: providing a first nonwoven layer that forms the outer cover; providing a second film layer that forms the backsheet, wherein the second film layer is free of apertures, wherein only the first nonwoven layer has a plurality of apertures defined therein, wherein at least some of the plurality of apertures are non-homogenous apertures, and wherein the laminate is free of elastic strands; applying a pre-strain force to only one of the first nonwoven layer or the second film layer, wherein the pre-strain force causes the first nonwoven layer or the second film layer to elongate by at least 5%; joining the first nonwoven layer to the second film layer while the first nonwoven layer or the second film layer is in a pre-strained condition; and releasing the pre-strain force to allow the first nonwoven layer or the second film layer to at least partially recover and form the three-dimensional laminate.
 17. The method of claim 16, wherein the plurality of non-homogenous apertures have a plurality of Interaperture Distances, according to the Aperture Test herein, wherein the Interaperture Distances have a distribution having a median and a mean, and wherein the mean is greater than the median.
 18. The method of claim 17, wherein the at least some of the plurality of apertures have melt-fused portions at least partially around perimeters of the apertures.
 19. The method of claim 16, comprising only applying the pre-strain force to the first nonwoven layer. 